GLOSS (low)

Low gloss can be defined as a dulling of the

product finish, usually caused by
insufficient force to push the molten plastic
against the steel surface of the cavity.

Also, optimize the cycle time to ensure the

material residence time is adequate to properly
melt the plastic.
LOW BARREL TEMPERATURES
Explanation: Low barrel temperatures have the
same effect as short residence time. The plastic
material does not become fluid enough to fill the
mold before solidifying and the material cannot be
forced against the steel of the mold cavity.
Therefore, the steel finish will not be replicated on
the plastic and a dull part will result.
Solution: Increase the barrel temperature to that
recommended by the material supplier. Adjust as
needed to eliminate the flow lines. And,
remember to keep the profile set so the material
is heated from the rear towards the front of the

MACHINE

barrel.

INADEQUATE INJECTION PRESSURE

LOW NOZZLE TEMPERATURE

Explanation: If too little injection pressure is used,

Explanation: As material is transported through

the molten plastic material will tend to cool off and

the heating barrel, it is gradually brought up to the

solidify before the mold cavity is packed. If no

ideal processing temperature by absorbing heat

packing is achieved, the material will not be

from the heating bands and frictional heat, which

forced against the mold cavity hard enough to

is created by the shearing action of the rotating

replicate the finish. The less dense material will

screw within the barrel. In the last heating zone,

appear dull and have very little gloss.

the material is exposed to is the nozzle. By the

Solution: Increasing the injection pressure will

time the material gets to the nozzle, it should

force the plastic against the steel of the mold

already be at ideal molding temperature and only

cavity and duplicate the gloss of the finish on that

a small amount of heat needs to be applied at this

steel.

point to keep the resin flowing. If the nozzle is not

INADEQUATE RESIDENCE TIME

hot enough, however, the material will begin to

Explanation: Residence time is the amount of

cool off too quickly as it leaves the barrel and the

time that the plastic material spends being

flow front will not be forced against the cavity

exposed to heating conditions in the injection

steel to squeeze out the flow lines.

barrel. The required time depends upon how

Solution: Increase the nozzle temperature. As a

much heat the material must absorb to be

rule-of-thumb the nozzle temperature should be

processed properly. Inadequate residence time

set at 10 degrees F higher than the setting for the

results in under heated material. This will cause

front zone of the barrel. This helps compensate

the material to be stiff when injected and it will not

for heat loss due to metal-to-metal contact

flow enough to fill the cavity before solidifying.

between the nozzle and the sprue bushing, and

The flow patterns will be imprinted on the surface

keeps the material hot enough to pack the mold,

of the molded part because they were not forced

eliminating low gloss.

out in time.

INADEQUATE CYCLE TIME

Solution: Optimize the residence time by making

Explanation: If the overall cycle time is too short

sure the mold is sized to the proper machine.

there is a good possibility that the material in the

barrel cannot absorb enough heat before it is

INADEQUATE VENTING

injected into the mold. This will cause premature

Explanation: If there is not enough venting in the

solidification and low gloss may appear because

mold, the material will push into the areas that are

the plastic was not packed out enough (before

not vented and will not compress against the

solidifying) to push against the steel cavity of the

mold steel because trapped gases are in the way.

mold and replicate the steel finish.

The material will actually solidify before packing

Solution: Increase the cycle time. The easiest

can be achieved. This early solidification will

change to make is to add time to the cooling

result in a dull surface finish.

portion of the cycle. That is when the plastic is

Solution: Vent the mold by grinding thin

absorbing the most heat in the barrel. Increase

(0.0005-0.002) pathways on the shutoff area of

barrel temperatures 10 degrees F at a time,

the cavity blocks. The viscosity of the plastic

allowing 10 cycles between changes to

being molded determines the depth of the vent.

re-stabilize the process.

Stiff materials can utilize deeper vents but fluid

MOLD

materials require thinner vents. In either case, the

LOW MOLD TEMPERATURE

concept is to remove air from the mold as fast as

Explanation: Generally, a hot mold will allow a

possible with as deep a gate as the material

material to stay molten longer than a cold mold

viscosity will allow. At least 30% of the parting line

and cause the molecules to pack against the

perimeter should be vented, but additional vents

mold steel before they solidify. This results in a

can be selectively placed for any area where

dense part with high gloss. If the mold is too cold,

localized low gloss occurs.

the molecules solidify before they are packed out

IMPROPER GATE LOCATION

and low gloss may result.

Explanation: With some plastics, if material is

Solution: Increase the mold temperature to the

injected directly across a flat cavity surface, it

point at which the material has the proper flow

tends to slow down quickly as a result of frictional

and packs out the mold. Start with the material

drag and cools off before the cavity is properly

suppliers recommendations and adjust

filled and packed. When this happens, the

accordingly. Allow 10 cycles for every 10-degree

molded part surface has low gloss because the

change for the process to re-stabilize.

material has not been forced against the cavity

SMALL GATES AND/OR RUNNERS

steel before solidification.

Explanation: Gates and/or runners that are too

Solution: Relocate or redesign the gate so that

small will cause excessive restriction to the flow

the molten plastic is directed against a metal

of the molten plastic. Many plastics will then

obstruction instead of across a flat surface. This

begin to solidify before they fill the cavity. The

will cause the material to disperse and continue

result is an unpacked condition of the molecules

to flow instead of slowing down.

and the material will not have a chance to be

POOR POLISHING OF CAVITY SURFACES

pressed against the cavity steel. Low gloss will

Explanation: A properly molded product will

result.

duplicate the finish that is present on the molding

Solution: Examine the gates and runners to

surfaces of the mold in which it was formed. If

determine if any burrs or other obstructions exist.

that finish was not properly prepared (normally by

If possible, perform a computer analysis to

hand polishing), the molded part will not have the

determine the proper sizing and location of gates

high gloss that is normally desired.

and runners. Ask the material supplier for data

Solution: Prepare the molding surface finish to

concerning gate and runner dimensioning for a

the requirements of the molded product. There

specific material and flow rate.

are industry standards available that describe the

degree of gloss required for specific finishes.

exists, some of the material may not absorb

These should be utilized to ensure consistency of

enough heat to travel far enough to pack the

finish on all molded products, and the finish

cavity and low gloss will occur because the

should be specified on the product drawing as

material cannot replicate the steel surface.

well as on the mold design.

Solution: If possible, operate the machine on

MATERIAL

automatic cycle, using the operator only to

IMPROPER FLOW RATE

interrupt the cycle if an emergency occurs. Use a

Explanation: Resin manufacturers supply

robot if an operator is really necessary. And,

specific formulations in a range of standard flow

instruct all employees on the importance of

rates. Thin-walled products may require an easy

maintaining consistent cycles.

flow material while thick-walled products can use

By Topworks plastic mold

a material that has a stiffer consistency. It is

better to use the stiffest flow possible because it
improves physical properties of the molded part.
However, the stiff material will require higher
injection pressures, which may blow the mold
open and cause loss of pressure, which results in
low surface gloss. If an easy flow material is used,
the physical properties will not be as great. In
addition, the material will maintain pressure and
create proper gloss.
Solution: Utilize a material that has the stiffest
flow possible without causing non-fill. Contact the
material supplier for help in deciding which flow
rate should be used for a specific application.
MOISTURE
Explanation: If moisture is present in the material
it will turn to steam during the transition through
the heating barrel, forming voids on the surface of
the molded part. Groups of voided areas will
gather to form a dull area because the underlying
plastic cannot replicate the steel surface of the
cavity.
Solution: Dry the material before
processing. All materials require drying, even if
they are not hygroscopic. After drying, the
material must be used within two hours or
moisture may return.
OPERATOR
INCONSISTENT PROCESS CYCLE
Explanation: It is possible that the machine
operator is the cause of delayed or inconsistent
cycles. This will result in erratic heating of the
material in the injection barrel. If such a condition