I. Rapid Qualitative Method-Short-Shot
Set the injection stroke to 80% of the total filling stroke and administer a brief injection. Eliminate any semi-finished products that are partially filled.
Visually compare the extent of the filling in all cavities. The initial filling uniformity is deemed adequate if the filling length deviation of all cavities is ≤2%.
There is no cost associated with testing, and only 1-2 test shots are required throughout the process, which should not exceed 5 minutes.
II. Method of Rapid Weight Verification
Use a standard electronic scale with an accuracy of 0.01g to weigh each cavity individually and continuously sample 20 complete moulds.
Determine the coefficient of variation (CV) for each product. The small-batch filling uniformity is deemed acceptable if the CV is less than 2%.
No coordinate measuring machines or other precision measuring equipment is necessary. Testing in a single batch, which is suitable for the majority of small-batch production scenarios, requires no more than 10 minutes.
II. Method for Rapid Defect Inspection
Visually examine all sampled products for differential defects, including flash, shrinkage marks, burning, and absent material in local cavities.
The filling uniformity can be rapidly determined to be normal if all cavity products exhibit a highly consistent appearance with no obvious defects.
A complete appearance inspection can be accomplished in just three minutes; no testing tools are necessary.
III. Pressure-Assisted Verification Method with Low Cost
In order to rapidly accumulate pressure profiles at each cavity filling stage, an external cavity pressure testing patch is implemented, which eliminates the necessity of embedding it within the mould.
The filling uniformity is deemed acceptable if the peak filling pressure difference is ≤7% and the overlap of the pressure curves for each cavity is ≥90%.
The testing patch is reusable; single-batch verification requires no more than 15 minutes, and the cost is only one-tenth that of embedded sensors.
This verification method is optimal for small-batch production scenarios, as it does not necessitate a substantial investment in testing apparatus and can promptly ascertain the uniformity of the filling process, thereby preventing the outflow of defective products in batches.
