Short lifespan of the mold: The mold often experiences problems such as damage, wear, and difficulty in demolding, resulting in a shortened lifespan. The solution includes selecting high-quality steel to make molds, strengthening mold maintenance, and adjusting injection molding process parameters reasonably.

Hot air holes and short shots: causing defects such as bubbles, hemorrhoids, and burrs on the surface of injection molded products. The solution includes increasing mold vent holes, optimizing injection molding process parameters, adjusting melting temperature and cycle, etc.

Plastic material aging: Under long-term storage or improper storage conditions, plastic materials are prone to aging, leading to a decrease in molding quality. The solution includes optimizing storage conditions, reasonable storage treatment, and timely updating of materials.

Thermal expansion and contraction problem: The shrinkage rate of injection molded parts after cooling is greater than the shrinkage rate of the mold, resulting in size instability, deformation, and other problems. The solution includes reasonable mold design, controlling injection temperature and pressure, and shortening cooling time.

Welding lines and short flow marks: During the injection molding process, when molten material converges from two or more channels, welding lines and short flow marks will form, affecting the appearance quality. The solution includes optimizing the flow channel design, increasing the fluidity of the molten material, and changing the injection temperature.

Color difference issue: The color and glossiness of injection molded products are inconsistent. The solution includes reasonable selection of plastic materials, control of injection molding temperature and pressure, and strengthening the ratio of color masterbatch and plastic materials.

Warpage and deformation issues: Injection molded parts experience warping and deformation due to uneven stress during the cooling process. The solution includes increasing the cooling time of injection molded parts, using auxiliary cooling equipment, adjusting mold temperature, etc.

Color mixing problem: When different batches of plastic materials or color masterbatches are mixed and used, color differences and unevenness may occur. The solution includes regular testing of plastic materials, strict control of the quality and dosage of color masterbatch, etc.

Pore problem: Pores appear on the surface or inside of injection molded parts, affecting their appearance and mechanical properties. The solution includes optimizing mold design, controlling injection molding process parameters, and increasing mold vent holes.

Thermal fatigue problem: Long term high-temperature injection molding can easily lead to material thermal fatigue, reducing the strength and toughness of injection molded parts. The solution includes selecting materials with good heat resistance, controlling injection temperature and cycle, etc.

Summary: Common problems and solutions in injection molding processes mainly include short mold life, empty hot holes and short shots, plastic material aging, thermal expansion and contraction, welding lines and short flow marks, color difference, warping and deformation, color mixing, porosity, thermal fatigue, and other issues. Reasonable selection of materials, optimization of mold design and process parameters, strengthening quality control and maintenance can effectively solve these problems and improve the manufacturing quality of injection molded parts.