https://www.avient.com/sites/default/files/resources/PolyOne%2520IR%2520Presentation%2520-%2520Jefferies%2520Conference%2520-%25208%253A7%253A2018.pdf
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Stringers
Bulkheads,
Decking and
Transoms
Doors and
Cabinetry
Ceilings
and Hatches
MECHANICAL PERFORMANCE
Superior strength-to-weight ratio
PROPERTY TEST
METHOD
PANEL THICKNESS
.50" .75" 1.00"
13 mm 19 mm 25 mm
Core Density* ISO 845
7 lb/ft3 7 lb/ft3 7 lb/ft3
115 kg/m3 115 kg/m3 115 kg/m3
Flexural Rigidity ASTM D7249
35,000 lb/in2
10.3 kg/m2
75,000 lb/in2
21.9 kg/m2
118,000 lb/in2
34.5 kg/m2
Areal Weight Calculated
0.89 lb/ft2
4.3 kg/m2
1.03 lb/ft2
5.0 kg/m2
1.17 lb/ft2
5.7 kg/m2
Core Shear Yield ASTM C393
101 psi
0.70 MPa
96 psi
0.66 MPa
88 psi
0.61 MPa
Max Load ASTM C393
357.5 lbs
162.2 kg
513.4 lbs
232.9 kg
551.1 lbs
250.0 kg
Core Shear ULT ASTM C393
113 psi
0.78 MPa
109 psi
0.75 MPa
94 psi
0.65 MPa
Face Bend Stress ASTM C393
9,008 psi
62.11 MPa
8,725 psi
60.16 MPa
7,542 psi
52.00 MPa
USES &
APPLICATIONS
* Additional core density panels are available in 5 lb/ft3 (80 kg/m3) and 8 lb/ft3 (135 kg/m3).
Example: Deflection for 24 inch panel = Chart value *[12 / 24]
Performance Comparison
Hammerhead Panels and Marine Plywood
TAB TESTING OF VARIOUS INSTALLATION METHODS
BREAK
PETG Skins with
1 in/25 mm
1.5 in/38 mm
2 in/51 mm
2400 lbs/1089 kg
2820 lbs/1279 kg
2748 lbs/1246 kg
Hammerhead with
5 lb/ft3 (80 kg/m3)
665 lbs
302 kg
Hammerhead with
7 lb/ft3 (115 kg/m3)
881 lbs
400 kg
Hammerhead with
1084 lbs
492 kg
770 lbs
349 kg
Glass/Epoxy with
1055 lbs
479 kg
Glass/Polyester
with Balsa Core
919 lbs
417 kg
L-Bracket Installation
BREAK
PETG Skins with
2375 lbs
1077 kg
770 lbs
349 kg
Glass/Polyester with
Balsa Core
797 lbs
362 kg
U-Channel Installation
ITW Plexus MA420
adhesive was used in all
tab testing installations
except where noted.
GL
AS
S/
EP
OX
Y
TA
B
M
AT
ER
IA
L
N
O
T
AB
BREAK
Hammerhead with
5 lb/ft3 (80 kg/m3)
420 lbs
191 kg
Hammerhead with
7 lb/ft3 (115 kg/m3)
2 in
370 lbs
168 kg
Hammerhead with
8 lb/ft3 (135 kg/m3)
332 lbs
151 kg
984 lbs
446 kg
Glass/Polyester
with Balsa Core
1298 lbs
589 kg
Hammerhead with
5 lb/ft3 (80 kg/m3)
Core Density -
ITW Plexus
MA420 Adhesive
NA 501 lbs
227 kg
Hammerhead with
7 lb/ft3 (115 kg/m3)
Core Density -
ITW Plexus MA420
Adhesive
NA 839 lbs
381 kg
Hammerhead with
8 lb/ft3 (135 kg/m3)
Core Density -
ITW Plexus
MA420 Adhesive
NA 1156 lbs
524 kg
Hammerhead with
8 lb/ft3 (135 kg/m3)
Core Density -
Crestomer
1152PA Adhesive
NA 1530 lbs
694 kg
Hammerhead with
8 lb/in3 (135 kg/m3)
Core Density -
Crestomer
M1-30 Adhesive
NA 1471 lbs
667 kg
Mixed Conditions
ADHESIVE
DESCRIPTION
ADHESIVE
GRADE MANUFACTURER
AVERAGE
BOND
STANDARD
DEVIATION
FAILURE
MODE
BEST ADHESION
2k Urethane 75421 Lord 2281 psi
15.73 MPa
184 psi
1.27 MPa
Substrate
Cohesive
2k Acrylic SA1-705 GRY1 AccraLock 2211 psi
15.24 MPa
78 psi
0.54 MPa Substrate
2k Acrylic Plexus MA420 ITW 2171 psi
14.97 MPa
262 psi
1.81 MPa Substrate
2k Acrylic SA10-05 Blk1 AccraLock 2102 psi
14.49 MPa
138 psi
0.95 MPa Substrate
2k Urethane 75451 Lord 2047 psi
14.11 MPa
68 psi
0.47 MPa Cohesive
2k Acrylic SA1-705 GRY 1:2 AccraLock 1966 psi
13.56 MPa
68 psi
0.47 MPa Substrate
2k Acrylic Scotchweld 8010 3M 1907 psi
13.15 MPa
61 psi
0.42 MPa Adhesive
Cyanoacrylate Gorilla Glue Gorilla Glue 1885 psi
13.00 MPa
432 psi
2.98 MPa Cohesive
2k Acrylic Crestabond PP-04 Scott Bader 1873 psi
12.91 MPa
281 psi
1.94 MPa Substrate
2k Acrylic SA10-05 Blk 10:2 AccraLock 1779 psi
12.27 MPa
127 psi
0.88 MPa Cohesive
2k Urethane 75422 Lord 1716 psi
11.83 MPa
190 psi
1.31 MPa
Cohesive
Adhesive
2k Urethane 75452 Lord 1535 psi
10.58 MPa
98 psi
0.68 MPa Adhesive
2k Methacrylate Polyfuse Icon
Containment
1610 psi
11.10 MPa
98 psi
0.68 MPa Adhesive
INTERMEDIATE ADHESION
2k Acrylic FA10-05 Blk
C010817 AccraLock 724 psi
4.99 MPa
58 psi
0.40 MPa Cohesive
2k Acrylic FA10-05 Blk1 AccraLock 722 psi
4.98 MPa
44 psi
0.30 MPa Cohesive
2k Epoxy Loctite Epoxy
Instant Mix Loctite 508 psi
3.50 MPa
81 psi
0.56 MPa Adhesive
2k Epoxy Gorilla Glue Epoxy Gorilla Glue 341 psi
2.35 MPa
198 psi
1.37 MPa Adhesive
NOT RECOMMENDED
2k Epoxy Loctite Epoxy
Marine Loctite 0 0 No bond
ADHESIVE SELECTION
Brands identified are owned by the manufacturers of the adhesive products.
1 surface sanded with 220 grit scuff prep 2 surface primed with 459T
FASTENER TYPE BENEFITS CONSIDERATIONS
Through-Bolting Best mechanical
locking system
Need back side
access to panel
Screw-In Anchor Highest pullout
strength Requires pilot hole
Cup Washer Spreads
compressive load
Requires relief hole;
For substructure and
hard point attachment
Wide Grip
(Bulb-Style)
Rivet
Ease of use—no
installation torque
limitations
For lower
load attachments
Sheet Metal or
Wood Screw
Readily available,
low cost
Penetrate both skins
for improved pullout
Shoulder Washer Limits
compressive load
Requires relief hole;
For substructure and
hard point attachment
For more information on installation, adhesives, and fasteners
for specific applications, please contact Avient.
https://www.avient.com/sites/default/files/resources/Innovation_Day_-_May_2014_0.pdf
Patricia Hubbard Global Technical Director
Specialty Engineered
Materials
PolyOne Corporation Page 6
Agenda
Time Topic Presenter
8:00-8:15 AM Welcome and Introduction Robert M.
Patterson
8:15-8:30 AM Financial Highlights and
Goals
Bradley C.
Richardson
8:30-8:45 AM Innovating for the Future Dr.
https://www.avient.com/sites/default/files/2020-09/stat-tech-tri-fold-processing-guide.pdf
Base Resin PC PC/PSU PES PEI PP ABS PEEK PA
Barrel Temperatures* °F (°C)
Rear Zone 530–560
(277–293)
550–575
(288–302)
660–700
(349–371)
675–725
(357–385)
390–420
(199–216)
425–460
(219–238)
680–730
(360–388)
430–500
(221–260)
Center Zone 515–560
(269–288)
540–565
(282–296)
650–690
655–710
(352–377)
380–405
(193–207)
415–450
(213–232)
670–710
(354–377)
420–490
(216–254)
Front Zone 510–525
(266–274)
530–555
(277–291)
640–680
(338–360)
655–700
(346–371)
370–395
(188–202)
405–440
(207–227)
410–480
(210–249)
Nozzle 520–535
(271–280)
540–565
(282–296)
650–690
665–710
(352–377)
380–400
(193–204)
415–450
(213–232)
660–700
(349–371)
420–490
(216–254)
Melt
Temperature
525–560
(274–293)
530–580
(277–304)
650–700
(343–371)
660–730
(349–388)
375–395
(191–202)
410–460
(210–238)
650–730
(343–388)
420–500
(216–260)
Mold
Temperature
175–250
(80–121)
160–220
(71–104)
280–350
(138–177)
275–350
(135–177)
100–135
(38–57)
150–180
(66–82)
300–425
(149–219)
160–230
(71–110)
Pack & Hold
Pressure
50%–75%
of Injection Pressure
Injection
Velocity
in/s
0.5–2.0
Back Pressure
psi 50
Screw Speed
rpm 40–70 40–70 40–70 40–70 40–70 40–70 40–70 40–70**
Drying
Parameters
°F (°C)
6 hrs @ 250
4 hrs @ 250
4 hrs @ 275
(135)
4 hrs @ 250
3 hrs @ 300
(150)
2 hrs @ 200
(93)
3 hrs @ 275
(135)
4 hrs @ 180
(82)
Cushion
in 0.125–0.250
Screw
Compression
Ratio
2.0:1–2.5:1 2.0:1–2.5:1 2.5:1–3.5:1 2.5:1–3.5:1 2.5:1–3.5:1 2.5:1–3.5:1 2.5:1–3.5:1 2.5:1–3.5:1
Nozzle
Type
General
General
General
General
General
General
General
Reverse
Taper
Clamp
Pressure 5–6 Tons/in2
* A reverse temperature profile is important to obtain optimum conductive properties.
PROBLEM CAUSE SOLUTION
Incomplete Fill Melt and/or mold
temperature too cold
Shot Size
• Increase nozzle and barrel temperatures
• Increase mold temperature
• Increase injection speed
• Increase pack and hold pressure
• Increase nozzle tip diameter
• Check thermocouples and heater bands
• Enlarge or widen vents and increase number of vents
• Check that vents are unplugged
• Check that gates are unplugged
• Enlarge gates and/or runners
• Perform short shots to determine fill pattern and verify
proper vent location
• Increase wall thickness to move gas trap to parting line
• Increase cushion
Brittleness Melt temperature too low
Degraded/Overheated material
Gate location and/or size
• Increase melt temperature
• Increase injection speed
• Measure melt temperature with pyrometer
• Decrease melt temperature
• Decrease back pressure
• Use smaller barrel/excessive residence time
• Relocate gate to nonstress area
• Increase gate size to allow higher flow speed
and lower molded-in stress
Fibers on Surface
(Splay)
Melt temperature too low
Insufficient packing
• Increase melt temperature
• Increase mold temperature
• Increase injection speed
• Increase pack and hold pressure, and time
Sink Marks Part geometry too thick
Melt temperature too hot
Insufficient material volume
• Reduce wall thickness
• Reduce rib thickness
• Decrease nozzle and barrel temperatures
• Increase shot size
• Increase injection rate
• Increase packing pressure
Flash Injection pressure too high
Excess material volume
Melt and/or mold
temperature too hot
• Decrease injection pressure
• Increase clamp pressure
• Decrease injection speed
• Increase transfer position
• Decrease pack pressure
• Decrease shot size
• Decrease injection speed
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Decrease screw speed
TROUBLESHOOTING RECOMMENDATIONS
PROBLEM CAUSE SOLUTION
Excessive Shrink Too much orientation • Increase packing time and pressure
• Increase hold pressure
• Decrease melt temperature
• Decrease mold temperature
• Decrease injection speed
• Decrease screw rpm
• Increase venting
• Increase cooling time
Not Enough Shrink Too little orientation • Decrease packing pressure and time
• Decrease hold pressure
• Increase melt temperature
• Increase mold temperature
• Increase injection speed
• Increase screw rpm
• Decrease cooling time
Burning Melt and/or mold
temperature too hot
Mold design
Moisture
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Clean, widen and increase number of vents
• Increase gate size or number of gates
• Verify material is dried at proper conditions
Nozzle Drool Nozzle temperature too hot • Decrease nozzle temperature
• Decrease back pressure
• Increase screw decompression
• Verify material has been dried at proper conditions
Weld Lines Melt front temperatures
too low
• Increase pack and hold pressure
• Increase melt temperature
• Increase vent width and locations
• Increase injection speed
• Decrease injection speed
• Increase gate size
• Perform short shots to determine fill pattern and verify
proper vent location
• Add vents and/or false ejector pin
• Move gate location
Warp Excessive orientation
• Increase cooling time
• Increase melt temperature
• Decrease injection pressure and injection speed
• Increase number of gates
Sticking in Mold Cavities are overpacked
Part is too hot
• Decrease injection speed and pressure
• Decrease pack and hold pressure
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Increase cooling time
• Increase draft angle
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
TROUBLESHOOTING RECOMMENDATIONS
www.avient.com
Copyright © 2020, Avient Corporation.
https://www.avient.com/resources/safety-data-sheets?page=4630
ROSE SC 3
HMF RED HOT UV PE 8
YELLOW PMS 3395 38 DBJ
https://www.avient.com/knowledge-base/article/overmolding-troubleshooting
Home //
Overmolding: Troubleshooting
https://www.avient.com/resources/safety-data-sheets?page=4178
PEARL GREEN #3
MNE31-38-7 Self Bond
PP FR 8-6 LMS-1000
https://www.avient.com/sites/default/files/resources/Investor%2520Day%2520-%2520May%25202018.pdf
INVESTOR DAY
O R L A N D O , F L O R I D A | M A Y 2 0 1 8
FORWARD
LOOKING
STATEMENTS
PolyOne Corporation 2
In this presentation, statements that are not reported financial results
or other historical information are “forward-looking statements” within
the meaning of the Private Securities Litigation Reform Act of 1995.
You are advised to consult any further disclosures we make on related subjects in our
reports on Form 10-Q, 8-K and 10-K that we provide to the Securities and Exchange Commission.
Investor Day Deck - Web
Investor Day
Forward �Looking �Statements
Factors that could cause actual results to differ materially from those implied by these forward-looking statements include, but are not limited to:
USE OF �NON-GAAP�MEASURES
Investor Day Agenda May 10, 2018
The Leaders Behind the Team
Introduction
Historic Past
Sustainability AT PolyOne
Safety First
the PolyOne Academy
Sustainably Impacting diverse End Markets
Products and Portfolio Optimization
OUR PLANET
Sustainability AT PolyOne
Adjusted EPS Expansion
Early years defined by Specialty �mix improvement
Commodity Pruning �Held Organic Sales Flat
Investment in Commercial Resources Driving Results
Sustainable Path to Double-Digit EPS Growth
Raising the Bar�ROIC drives shareholder return
Commercial Excellence
STRATEGIC INVESTMENT IN 3 KEY AREAS
Key Commercial Investments
New Resources Fueling the Future
Aligning with trends for Growth
Innovation
3 Horizons of Development
3 Horizons of Development
3 Horizons of Development
Innovation Pipeline
Innovation Drives Earnings Growth
IQ DESIGN LABS
3D Printing�Bringing New ideas to life
LSS CUSTOMER FIRST
The Evolving Customer Relationship
Slide Number 37
Inspired future
Innovating with PolyOne
PolyOne Distribution
DISTRIBUTION
Service is our business
Service is our business
Key Commercial Investments
Growth through Inside Sales
Growth through Multiple Sales Channels
New Resources Fueling the Future
Inspired future
Specialty Engineered Materials
Specialty Engineered Materials
Specialty Engineered Materials
Capitalizing on the global market
STRATEGIC INVESTMENT IN 3 KEY AREAS
Key Commercial Investments
New Resources Fueling the Future
growth Through Service
Innovation Spotlight: Composites
Composites Refresher
Strategic Investment History
COMPOSITES in Transportation
Slide Number 61
Inspired future
Performance Products �& Solutions
Performance Products & Solutions
Performance Products & Solutions
STRATEGIC INVESTMENT IN 3 KEY AREAS
Key Commercial Investments
New Resources Fueling the Future
Growth Through Service
Growth Through Service
Innovation Spotlight: �Flame Retardant�Polymers
FLAME RETARDANT �DRIVERS
Flame Retardant Performance Spectrum
LED Solutions
Inspired future
Color Additives�& Inks
COLOR, ADDITIVES & INKS
Color, Additives & Inks
Capitalizing on the global market
STRATEGIC INVESTMENT IN 3 KEY AREAS
Key Commercial Investments
New Resources Fueling the Future
Growth Through Service
Innovation Spotlight: Additive & Colorant�Technologies
Barrier Technologies
Fiber Colorants
Strategic Investment History
Slide Number 88
Slide Number 89
COLORMATRIX SELECT™
Enabling the Customer
Slide Number 92
Inspired future
M&A Review
Over a decade of successful specialty acquisitions
Invest-to-Grow Strategy
Invest-to-Grow Playbook
Invest-to-Grow Proof of performance
Invest-to-Grow Proof of performance
Invest-to-Grow Driving the future
Invest-to-Grow Driving the future
Strong Pipeline�driven by fragmented Market
Summary
Financial Review
Adjusted EPS Expansion
Strategic cash deployment
Proof of Performance �Expanding Margins & ROIC
Investment in Commercial Resources Driving Results
Sustainable Path to Double-Digit EPS Growth
ROIC drives shareholder return
ROIC drives shareholder return
Conclusion
Investor Presentation - May 2018 Non-GAAP
Investor Presentation - March 2018
https://www.avient.com/sites/default/files/2020-08/2020-hammerhead-application-install-guide.pdf
MARINE PLYWOOD
Hammerhead™ panels are three times lighter than marine plywood
MOISTURE ABSORPTION % weight change due to water absorption for selected
composites and marine plywood
10000
60000
110000
160000
210000
260000
310000
360000
0.5 0.75 1 1.25 1.5
F
le
x
u
ra
l
R
it
y
-
lb
/
2
Panel Thickness - in
Hammerhead™ 5.3lb/in^3 Core Density Hammerhead™ 8.4lb/in^3 Core Density Plywood
— Hammerhead™ 5.3 lb/ft3 Core Density
— Hammerhead™ 8.4 lb/ft3 Core Density
— Marine Plywood
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
0 10 20 30 40 50 60 70 80 90 100
%
W
t
C
a
g
Immersion Time - Days
.50" Hammerhead™ .75" Hammerhead™ 1" Hammerhead™ 1.50" Hammerhead™
.50" marine plywood .75" marine plywood 1" marine plywood
Fl
ex
ur
al
R
ity
-
lb
-in
2
INSTALLATION INSTRUCTIONS
CUTTING & DRILLING
Recommended blade: Industrial fine cut-off saw blade, 10" x 80 teeth 38° ATB grind with 5/8" bore,
PTFE coating
Recommended router bits: 3/8" diameter, 4 flute TiAlN (titanium aluminum nitride) coated carbide bit
FORMING
Apply localized 400˚F heat at a length proportional to the panel thickness (see equation below)
and bend to shape.
BREAK STRENGTH
(LBS)
Hammerhead™
with 5.3 lb/ft3
2 in 420
Hammerhead™
with 8.4 lb/ft3
2 in 332
Marine Plywood 2 in 984
Glass/Polyester with
Balsa Core 2 in 1298
Hammerhead™
with 5.3 lb/ft3
Core Density -
ITW Plexus
NA 501
Hammerhead™
with 8.4 lb/ft3
Core Density -
ITW Plexus
NA 1156
Hammerhead™
with 8.4 lb/ft3
Core Density -
Crestomer
1152PA Adhesive
NA 1530
Hammerhead™
with 8.4 lb/in3
Core Density -
Crestomer
M1-30 Adhesive
NA 1471
ADHESIVE
DESCRIPTION
ADHESIVE
GRADE MANUFACTURER
AVERAGE
BOND
STRENGTH
(PSI)
STANDARD
DEVIATION
FAILURE
MODE
BEST ADHESION
2k Urethane 75421 Lord 2281 184 Substrate
Cohesive
2k Acrylic SA1-705 GRY1 AccraLock 2211 78 Substrate
2k Acrylic Plexus MA420 ITW 2171 262 Substrate
2k Acrylic SA10-05 Blk1 AccraLock 2102 138 Substrate
2k Urethane 75451 Lord 2047 68 Cohesive
2k Acrylic SA1-705 GRY 1:2 AccraLock 1966 68 Substrate
2k Acrylic Scotchweld 8010 3M 1907 61 Adhesive
Cyanoacrylate Gorilla Glue Gorilla Glue 1885 432 Cohesive
2k Acrylic Crestabond PP-04 Scott Bader 1873 281 Substrate
2k Acrylic SA10-05 Blk 10:2 AccraLock 1779 127 Cohesive
2k Urethane 75422 Lord 1716 190 Cohesive
Adhesive
2k Urethane 75452 Lord 1535 98 Adhesive
2k Methacrylate Polyfuse Icon
Containment 1610 98 Adhesive
INTERMEDIATE ADHESION
2k Acrylic FA10-05 Blk
C010817 AccraLock 724 58 Cohesive
2k Acrylic FA10-05 Blk1 AccraLock 722 44 Cohesive
2k Epoxy Loctite Epoxy
Instant Mix Loctite 508 81 Adhesive
2k Epoxy Gorilla Glue Epoxy Gorilla Glue 341 198 Adhesive
NOT RECOMMENDED
2k Epoxy Loctite Epoxy
Marine Loctite 0 0 No bond
ADHESIVE SELECTION
Brands identified are owned by the manufacturers of the adhesive products.
1 surface sanded with 220 grit scuff prep 2 surface primed with 459T
FASTENER TYPE BENEFITS CONSIDERATIONS
Through-Bolting Best mechanical
locking system
Need back side
access to panel
Screw-In Anchor Highest pullout
strength Requires pilot hole
Cup Washer Spreads
compressive load
Requires relief hole;
For substructure and
hard point attachment
Wide Grip
(Bulb-Style)
Rivet
Ease of use—no
installation torque
limitations
For lower
load attachments
Sheet Metal or
Wood Screw
Readily available,
low cost
Penetrate both skins
for improved pullout
Shoulder Washer Limits
compressive load
Requires relief hole;
For substructure and
hard point attachment
For more information on installation, adhesives, and fasteners
for specific applications, please contact Avient.
https://www.avient.com/sites/default/files/2022-06/Maxxam FR Injection Molding Processing Guide.pdf
Drying non-halogenated materials is suggested.
2 hours @ 100 (38)
Moisture Range
(%)
Not required
Follow up by purging machine with general
purpose PP
• Residence time should not exceed 5 minutes for Maxxam FR products
• General ventilation is suggested
Shut Down
• Purge the equipment with a general purpose PP
• All tooling and equipment must be free of any residual Maxxam FR upon
shut down
• Continue generating parts made from the natural PP until clear
• Wipe down tool steel with mold cleaner
• When using a hot runner system, care must be taken to remove residual
product from the manifold
MOLD DESIGN RECOMMENDATIONS
Cold Slug Wells
• Place cold slug wells at the base of the sprue to capture the cold material first
emerging from the nozzle
• Place cold slug wells at every 90° bend in the runner system
• Well depths approximately 2–3 times the diameter of the runner provide best
results
Draft Angle • Draft angle should be 1/2°–1° per side.
Vents should be placed at the intersection of each 90° bend in the runner
system off of the cold slug well and vented to atmosphere
Black Specks
Contamination
• Purge barrel with general purpose PP
• Verify correct nozzle is being used
• Pull screw for cleaning
Degraded/overheated
material
• Decrease melt temperature
• Decrease injection speed
• Use appropriately sized barrel
Brittleness
Degraded/overheated material
• Decrease melt temperature
• Decrease injection speed
• Use appropriately sized barrel
Gate location and/or size
• Relocate gate to nonstress area
• Increase gate size to allow higher flow rate and
lower molded-in stress
Burning
Process related
Mold design • Clean, widen and increase number of vents
• Increase gate size to reduce shear
Fibers/Minerals on
Surface or Uneven
Surface Appearance
Melt temperature too low
• Increase injection speed
Insufficient packing • Increase hold pressure and time
Flash
Injection pressure
too high
• Decrease injection pressure
• Increase clamp pressure
• Increase transfer position
Excess material volume
• Decrease pack pressure
• Decrease shot size
Melt and/or mold too hot
• Decrease screw speed
Loose clamp • Reset mold height
• Increase clamp tonnage
Troubleshooting Recommendations
Incomplete Fill
Melt and/or mold too cold
• Increase nozzle and barrel temperatures
Mold design
• Enlarge or widen vents and increase number
of vents
• Check that vents are unplugged
• Check that gates are unplugged
• Enlarge gates and/or runners
• Perform short shots to determine fill pattern
and verify proper vent location
• Increase wall thickness to move gas trap to
parting line
Shot size • Adjust transfer position to 98% full
Nozzle Drool Nozzle temperature too hot
• Decrease nozzle temperature
• Increase screw decompression
Shrink
Too much shrink • Increase cooling time
Too little shrink • Decrease cooling time
Sink Marks
Part geometry too thick • Reduce wall thickness
• Reduce rib thickness
Melt too hot • Decrease nozzle and barrel temperatures
Insufficient material
volume
• Increase packing pressure
Troubleshooting Recommendations (continued)
Sticking in Mold
Overfilled cavity
• Decrease injection rate and pressure
• Decrease hold pressure
• Decrease cooling time
Mold design • Increase draft angle
• Polish cores in direction of ejection
Part is too hot
• Increase cooling time
Warp
Process related
• Increase cooling time
• Increase pack pressure
• Increase pack time
Mold design • Inspect for non-uniform mold cooling
Part design • Inspect for non-uniform wall thickness
Temperature control unit
incorrect temperature
• Check settings
• Inspect thermocouple
Weld Lines
Melt front temperatures
are too low
• Increase pack and hold pressure
Mold design
• Increase gate size
• Perform short shots to determine fill pattern
and verify proper vent location
• Add vents and/or false ejector pin
• Move gate location
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