An Investigation to Reduce the Effect of Moisture on Injection-Molded Parts through Optimization of Plasticization Parameters

Plastic materials can absorb moisture from the atmosphere even after drying. This absorbed moisture can cause many defects in the molding process. Conventionally, a dryer is used to reduce the moisture content. However, the use of a drying unit involves huge daily power consumption and is also time-consuming. Therefore, this study proposed a new method to reduce the impact of moisture on molded product part quality through the optimization of plasticization parameters while reducing drying time. Two plastic materials, polyurethane (TPU) and polycarbonate (PC), were used for the experimental verification. Key plasticization parameters, including back pressure, screw rotation speed, and barrel temperature were chosen; their influence was investigated by the design of experiments (DOE). Moisture-induced defects, such as air bubble area, part surface gloss, and appearance were measured and correlated with the plasticization parameters. It was found, after optimization via a three-level DOE and factorial design multivariate statistical analysis using TPU, that the gloss (GU) of the PC part without drying was very close to that (98.4 GU) of the fully dried PC. The proposed methodology may help molders to improve production efficiency and achieve cost savings.