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Cosmetic Specifications of Injected Molded Parts

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331 views26 pages

Cosmetic Specifications of Injected Molded Parts

Uploaded by

Alfredo Ugalde
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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or INJECTION Specifications for Molders snk Sponsored by the Molders Division of The Society of the Plastics Industry, Inc. The Socicty of the Plastics Industry Cosmetic Specifications of Injection Molded Parts ‘This specification has been prepared by the Molders Division of The Society of the Plastics Industry, Inc. as.a service to its members and their customers ‘The specification provides recommendations only. It is up to the molder and customer to determine particular contractual arrangements. © 1994 The Society ofthe Plastics Industry, Inc. Acknowledgement The SPI Molders Division is indebted to Carl Kern, Director of Quality, BACE Manufacturing, Inc., for his dedication to the development of this guide as its principal author and layout-designer. ‘The Division also wishes to thank Mike Noggle, CKO, BACE Manufacturing, Inc. (and Moldeis Division Dircctor-at- Large) for BACE’s generosity in providing the contents of the original draft. We also acknowledge Mr. Noggle’s leadership towards achieving the published document. Questions or comments should be directed to: Molders Division ‘The Society of the Plastics Industry, Inc. 1801 K Street, N.W., Suite 600K. Washington, DC 20006-1301 Phone: 202/974-5200 Fax: 202/296-7005 www.socplas.org Version A Reprinted: February 1999 The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts Table of Contents page I. Defect Definitions 2: IL. Surface Identification and Classification of Surface Finish 8 III, Standard Viewing Condition 9 IV. Color Matching 10 V. Gloss 10 VL. Surface Finish and Texture Matching i ‘VIL Adhesion uw Cosmetic Quality Summary Sheets 12 Appendix 17 © 1994 The Society of the Plastics Industry, Inc, Version A The Society of the Plas s Industry Cosmetic Specifications of Injection Molded Parts TITLE: ‘Cosmetic Specification of Injection Molded Parts PURPOSE ‘The purpose of this standard is to provide quantitative definitions, and recommended ‘methods of inspection and measurement of the cosmetic quality attributes in the absence of customer provided specifications. The definitions, descriptions and classifications contained in the specification arc based on typical terms used in the injection molding process and, where applicable, also relate to post molding activities. SCOPE, This specification addresses the cosmetic quality of molded plastic parts and related post molding ectivities Page 1 © 1994 The Society of the Plastics Industry, Inc. Version A. The Society of the Plast s Industry Cosmetic Specifications of Injection Molded Parts 1, DEFECT DEFINITIONS BLEEDING (paint or decoration) Evidence of one color overlaping or altering another color (painting). Speading of pigment beyond the intended boudries (silk screen, printing) BLUSH Discoloration or change in gloss, Generally occurring at gate locations or abrupt changes in wall thickness, BROKEN General damage. For example bent and/or broken tabs or ribs. BUBBLES Void pockets, typically seen only in transparent parts, May appear as a bulge or protrusion in an opaque part. BURNS Brown marks or streak, (Also ace gas marks.) COLD SLUG First material to enter mald during injection. Solid or semi-solid, this material leaves a distinct border with adjacent melted material similar in appearence to weldlines Page 2 © 1994 The Society of the Plastics Industry, Inc. Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts CONTAMINATION Large areas of discoloration from foreign matter or foreign material embedded in the surface of a part. t CRACKING Stress induced splitting or fissures causing separation of material CRAZING Multiple tiny cracks due to stress exerted on the part. DELAMINATION Separation (peeling) of layers of plastic DISCOLORATION Any change from the original color standard. Unintended, inconsistent culo DRAG MARKS Clusters of scratches from plastic dragging against mold details when a part is jected fiom a mold. EILL-INS (print or silk screen) An execssive use of ink that alters the form of screened or printed feature, Placement of ink where no ink should be. Page 3 © 1994 The Society of the Plastics Industry, Inc Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts FLASH Excess plastic at parting line or mating surface of the mold, Normally very thin and flat protrusion of plastic along an edge of a part. Can also appear as a very thin string or thread of plastic away from the edge of a part (string flash). Often found at vents, knock outs and other shut-off areas FLOW MARKS (paint or silk screen) Waviness of edge or excessive linear junction between two surfaces of ink or paint GAS MARKS Dark discolored streaks caused by incomplete venting of gases generated during, the molding cycle jOUGE Surface imperfection due to abrasion that removes small amounts of material. Deptt is micasurable, GREASI ‘Any type of machine lubrication an the surface of @ part HAZE Cloudiness on an otherwise transparent part. Page 4 © 1994 The Society ofthe Plastics Industry, Inc. Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts INSERT PROBLEMS (Not a true "cosmetic" defect. Mare finetianal than cosmetic) Errors related to the installation of inserts into plastic parts, Inserts can be set too high or too low in a socket or boss. They can also be damaged or misaligned and may even be missing JETTING See splay ANE (paint) Any unintended foreign substance in the coating or on the surface. MARBLING Colored streaks caused by incomplete mixing of 2 different colored plastics, Also referred to as streaking NICKS Like gouges but of short length. Cause by impact rather than abrasion. NON-ADHESION (painted or decorated)) Lack of adequate sticking of paint, print or any coating to the plastic surface. ORANGE PEEL Rippled or mottled appearance view able as concentric lines. Caused by under pressurizing, Orange peel is often the first sign of possible sink or shorting, Page 5 © 1994 The Society of the Plastics Industry, Inc. Version A. The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts PIN PUSH Protrusion or distortion caused by an ejector pin pushing into part more than normal. The protrusion is most evident on the surface opposite the ejector pin. PITTING Crater-like imperfections on the surface of the part. PULLING Part distortion caused from plastic catching in the mold when the part is ejected RUNS (painting or printing) Dripping or sagging of paint or ink. Movement of ink beyond intended surfaces. Usually caused by too much or too thick paint or ink. SCRATCH ‘Surface imperfection due to abrasion that removes small amounts of material, Depth is not measurable, Differs from scratch in mold which leaves a consistent mark. SHINE Glossy or shiny areas on textured surface. Usually caused by a dirty or worn mold. Can also be caused by lack of sufficient pressure to properly replicate texture in the mold. Page 6 ‘© 1994 The Society ofthe Plastics Industry, Inc Version A The Society of the Plasties Industry Cosmetic Specifications of Injection Molded Parts SHORTS (Short shot, non-fill) “Missing plastic duc to incomplete filling of the mold cavity. Parts are not completely formed. Can usually be identified by smooth, shiny and rounded surfaces. SINK Surface depression caused by non uniform material solidification and shrinkage. Most often noted at intertace between dittering wall thicknesses. ‘SMEARING (paint or ink) ‘Similar to bleeding. Excess ink or paint in areas that should be free of ink or paint. ‘Smearing is due to rubbing of surface before adequately dried SPECKS Small discolored points of matter embedded in the surface. Typically black, caused by material contamination or material degradation. SPLAY Off colored streaking. Usually appears silver-like. Splay is caused by moisture in the material or thermal degradation of the resin during processing, A similar look can be caused by cold material skipping across the surface during a fast fll. This is commonly called "jetting" WELDLINES Witness line where 2 or more fronts of molten plastic converge. Also called knitlines or flowlines. Page 7 @ 1994 The Society ofthe Prastics Industry, Inc. Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts Il, SURFACE IDENTIFICATION AND CLASSIFICATION OF SURFACE FINISH A. SURFACE FINISH. GRADE 1 - «Highly polished: (e.g. SPI- B1 or lower). © Clear transparent ‘Fluid contact - (primarily applies to medical parts) GRADE 2 - = Low grade polish, non-textured: (¢.g. SPI - B2 or higher ) + Textured. «© Clear translucent. GRADE 3 - = Painted parts GRADE 4- + Ink stamped, printed, silk screened + Other decorative processes. B. SURFACE IDENTIFICATION The top or front, most often viewed surface. Generally the front edge and sides of a part, Not viewed as often as an "A" surface but easily seen by user. Most often, the back and bottom surface. internal surfaces. Normally D surfaces are not inspected for cosmetic attributes. Where, necessary, D surface inspection will be specified as an exception Page 8 © 1994 The Society ofthe Plastics Industry, Inc. Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts III. STANDARD VIEWING CONDITION A. LIGHTING INTENSITY All quality decisions of cosmetic acceptability will be made under normal lighting conditions (80-120 footcandles) in white fluorescent light. B, VIEWING ANGLE All viewing will take place with direct overhead lighting, Viewing angle is dependent on surface classification. In every case, parts will be held such that the light is NOT REFLECTED directly to the viewer. "A" surface - Hold part 30° from the horizontal plane. Part is in direct line with your eyee, ROTATE part 30° to the right and to the left about the vertical axis. "DB" surface - Hold part 900 from the horizontal plane Part is in direct line with your eyes. DO NOT rotate the part, Hold part 90° from the horizontal plane. Part is NOT in direct line with your eyes. Part is held 45° below the plane of your eyes. DO NOT rotate the part. C. VIEWING DISTANCE "A" surface - 18 inches surface - 24 inches *C" surface - 30 inches Page 9 © 1994 The Society of the Plastics Industry, Ine. Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts IIL STANDARD VIEWING CONDITION (continued) D. INSPECTION INTERVAL (time) Inspection interval is a function of surface area. mA ‘noe! SURFACE AREA Surfaces Surfaces <4in2 ("x2") 2 sec, 1 see. 4-16 in? (4"x 4") 4 sec. 2 sec. 16-64 in? (8" x 8") 6 sec. 3 sec. 64-144 in? (12" x 12") 8 sec. 4 sec >14dine — (12"x 12") 10 sec. 5 sec. IV. COLOR MATCHING Decisions regarding color matching are made by comparison to known standards using a spectrophotometer, color meter or suitable color matching light booth. Color standards and tolerances shall be provided by the customer. In the absence of a customer supplied color standard, standards shall be developed based upon the material manufacturer's color chip set and tolerances shall be set using a Delta E (AE) limit of 1.00, unless otherwise stated by the customer. V. GLOSS. Determination of gloss is to be made using a suitable glossmeter (e.g. BYK Gardener Glossgard® 60° glossmeter). When gloss cannot be measured by glossmeter, judgement shall be made by eye against gloss standards pravided hy or approved hy the customer. All evaluations by eye shall be under standard viewing conditions Page 10 © 1994 The Society ofthe Plastics Industry, Inc. Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts VI. SURFACE FINISH and TEXTURE MATCHING. Judgement as to the conformance of surface finish is to be made by comparing a part to an SPI Mold Finish Guide plaque. Comparison is by eye unless otherwise specified by the customer. Judgement as to the conformance of surface texture is to be made by comparing a part to a Mold-Tech texture plaque, Comparison is by eye unless otherwise specified by the customer. VI. ADHESION Adhesion requirements pertain to printed, painted or other decorative finishes applied to the surtace of a plastic part. The applied finish mnst withstand a tape test, wherehy a piece of pressure sensitive tape (Scotch Number 610 or equivalent adhesive strength) is applied across the finished surface. The tape is then removed by rapidly pulling the tape at a 90 degree angle to the part surface, The tape is examined for evidence of finish coat removal. There should be nu evidence of finish coat on the tape. Page 11 1994 The Society of the Plastics Industry, Inc. Version A. The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts COSMETIC QUALITY SUMMARY SHEETS The following four pages are summary sheets outlining the cosmetic requirements by grade. Page 12 © 1994 The Society of the Plastics Industry, Tne Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts JKADL 1 (Highly polished, clear transparent, flutd contact) SURFACE A B c WELDLINES, "ite fe ISH and WELDLINES are established in greoment wih customer & BLUSH nd hod based up iit srples SINK None allowed 03" max. 10" max SPECKS & ACCEPTIF- Lessin orequal es than equal Less than o equal BUBBLES 10.010" Nocloeer 1 10". Noclesor 12 O17" Noctoser ‘han iach than Tinh than ine ALLOWABLE .010"-.025" 010"- 025" or030 RANGE, “Allow 1 per 16 inch? ‘Allow 2 per 16 inch? “Allow 4 per 16 inch? axe (ara) Nolaser (are) Nocorer than 2 inches ‘han Dincher REJECT IF- Greater than 025° Greterthan 025° Grete tan 030" SCRATCHES ACCEPT IF = 130° or less in lent, 300" ores in Lent low 1 per 16 inch? ‘Allow 2 per 16 inch? area! (ree) (44), No closer than inch REJECT IF- Greater han 100° Grater than 150" Greater than 300° SPLAY Ne Allan None Allen Refer to iit amis BURNS . * corte exceptions in GAS MARKS . . uaity Pn. MARRIING . . . ORANGE PEEL 2 i NON-UNIKORM TEXTURE * i . PITTING . " CRACKING . a “ CRAZING . F = FT AMINATION : . . COLD SLUGS . a ; Page 13 © 1994 The Society of the Plastics Industry, Inc. Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts GRADE 2 - (Low grade polish, textured, clear translucent) SURFACE A B c WELDLINES Limits for BLUSH and WELDLINES are established in agrcement wih castomer & BLUSH a old based upon iit samples SINK None alowed 005" max 1s" max, SPECKS & ACCEPT IF. Lesthanoe oqusl Less than o equal Less tha o ual BUBBLES to.010" Nocloser to 010". No cess 10.018" Noose than I inc ‘han ech ‘han ech ALLOWABLE —_00"-.030" 10"-.030" 15". 040% RANGE ‘low 1 per 16 ini? Allow 2 pe 16 inch? ‘Allow 3 pr 16 inc? carey) (Ur) No close (ara) No closer ‘han 2 inches, han ac, REICCTIF-— Gresterthan 030" restr than 050% Gretr than. 040°, SCRATCHES ACCEPTIF- 150" ores in length 200" or ls in length 300" ores in length ‘Allow 1 per 16 ine? ‘Allow I per 16 inh? Allow 3 per 16 ine? (rea, axa, ("x4"). No closer than inch REJECTIF- Greater then 150" Greater than 200" Grestr than 300° SPLAY None Allowed None alowed Refer to init samples BURNS * " or note exception ia GAS MARKS " : Quality Plan MARBLING “ . = ORANGE PEEL ‘ : * NON-UNIFORM TEXTURE ~ : PITTING : CRACKING " i * ‘CRAZING . DELAMINATION COLD SLUGS s ¢ 5 Page 14 © 1994 The Society of the Plastics Industry, Ine. Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts GRADE 5 - (Painted / Finished parts) STIRFACE A B c SPECKS, DISCOLORATION, & GLOSSINESS ACCEPTIF. —Lessthanor equal Les than o equal ‘Less han or equal 10.010" Nodloser to. 018". Noles 01s ‘ha inch ‘han ec ALLOWABLE 010"-.020". 15-040" 13". 050" RANGE, ‘Allow 2 per 1s inc’ ‘Allow 4 per 16 inch? ‘Alo 6 pr 16 inch? area, (rx Nocloser (area) Nociser Maat in thee Liao REJECT F= —Gresterthan 020° rats han 040". Grattan 50" SCRATCHES & LINT ACCEPTIF- 010*x 030" or lss 020" x.050" or less, (020 x.500" ores. ‘Allow 2 per 16 inci? lon A per 6 not lls par 16 at? (4° x4"), No closer than (rxd") No closer than (4° x4). Nocloser than Vine, inet, Vine REJECTIF- Greaterthan O10"x.030" Greater than 020" x.030" (eater tban 020x900" MARKS & RUNS ACCEPTIF- none (020° x.050° or less. (020 x. 500" or less, ‘Allow 2 pe 16 inch? Allow pe 16 ine? (a x4"), No closer than (4"x4"), No loser than inch Tinen REJECTIF- any found Greater than 020" x.050" Greater than 020" x. 500" IN-ADHESION OR NON-UNIFORM COVERAGE ACCEPTIE ome. 125° or less 250" or less. Allow 2 per 1 inch? {Allow 4 per 16 inc’ Gna) Nselosa than (4" 24", No closer than inh ind, REJECTIF- any found Greater than 125" Greater than 250" Page 15 © 1994 The Society ofthe Plastics Industry, Inc Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts GRADE 4 - (Decorated Parts - stamped, printed, silk screened, in-mold,... ec.)) SURFACE, A B c ‘SPECKS, VOIDS & FILLINGS ACCERTIF- Les than equal Leshan or oat fan ich ALLOWABLE 010"- 020" 15°. 030" 025". 050" RANGE ‘allow 2p 16 in? iow poe 16 neh? ‘Allow 3 per 16 inet? rea No closer. (6x4) Nocloser (axa) Nockser than 2 inca ‘ha iach than inch RENECT IF Greterthan 020" Geaterthan 00" renter than. 050" FLOWMARKS & INCONSISTENCIES ACCEPTIF-—noneallowed 020" ores 050" ores. Allow 2 per surface Allow 4 per surface Noose han | inch No loser than 1c, REJECTIF- any found Greate than 020" Greater then 050" SMEARING, BLEEDING & HAZE ACCEPT IF- none lloned 020" orless. 50" or leas. ‘Allow I per surface ‘Allow 2 per surface | Neelneer than Heh [No close than 1 inc, | REJECTIF- any found (Greater than 020" Greater than.0S0" Page 16 © 1994 The Society of the Plastics Industry, Ine. Version A The Society of the Plastics Industry Cosmetic Specifications of Injection Molded Parts APPENDIX The following four pages are work sheets outlining the cosmetic requirements by srade and are intended to be used as work instructions ar the job site Their use 1s optional and the sheets are provided merely as a tool in the implementation and integration of cosmetic evaluation during the manufacturing process (as opposed to afier the process) The pages of the appendix may be photocopied. Poge 17 © 1994 The Society of the Plastics Industry, Inc Version A I The Society of the Plastics Industry Cosmetic Specifications Gitomer Part Name: Part Number: Authorized by. Light GRADE 1 (Highly polished, clear transparent, fluid contact) ARR SURFACE A R c WELDLINES {inte foe BLUSH sd WELDLINES ar ait in growth tomar & BLUSH and held based upon init sles SINK None alowed 03" max 10"max 8 <—_|] SPECKS & ACCEPTIF- Lessthmor ena Lesthan equal Les than or equal | | BUBBLES 0.010", No corer 0.010% No closer to 012", No closer LJ tha Lick than inc ‘han inch c ALLOWABLE 010"-.025. a10"-025", O12"- 030, RANGE. ‘Allow i peri inc ‘Mow 3 pr 16 ich ‘Allow 4p 6 inh sn G4 No der (axa. No closer ‘han inches. Ahan ince. el REMECT I= —Gresterthan.025" ‘Grete than 025°. ‘Grater than 030 30°\ L] SCRATCHES ACCEPT IF 100" oes in enath 150" ores in lena 300" oes in feng ‘Allow t pee 16 inch™ Allow T per 16 ine ‘Allow 2 per 16 inc? creat crea. (axa No closer than inch REJECT IF- reste than 100" Greater than 150" Greater han 300" spray Now Aon Non ont Ratt it ae BURNS : . cr ot exception in GAS MARKS ® = daly Pan MARRLING : : . ORANGE PEEL, . ‘ . NON-UNIFORM TEXTURE * ‘ PITTING : : . CRACKING : fs CRAZING . * DELAMINATION : : . COLD SLUGS € : : © 1994 The Society of the Plastics Industry, Ine. Version A The Society of the Plastics Industry Cosmetic Specifications Cutomer: Part Name: Part Number: Authorized by GRADE 2 - (Low grade polish, textured, clear translucent) SURFACE A B c WELDLINES Limits for BLUSH and WELDLINES are etablisod in agreement with user & BLUSH dha based upon iit saplos 8 SINK None allowed 005" max. 15" max. SPECKS & ACCEPTIP. Lessttan oe Les thane Lathan ore BUBBLES tb.0107Nocler 40.010" No our {0.0187 Nolte : than nc than ih ‘tan ack ALLOWABLE 010"-.020 010-030: ors" 040 RANGE Allow pe sinc? ‘low 2 pe 6c? ‘lw’ pri ore Gorey Nocier Gees Nectar than 2 ines ‘han ck REIECTIP- eset. 030 rete tan 030: Crete tan SCRATCHES "ACCEPTIF- 150" ot less in length 200 or ess in length, 300" or less i ent “Allow I pe 16 inch? Allow 1 per 16 inch? ‘Allow 3 per 16 inch? xa, area, (47 x4") No loser than Lined, REJECT IF. (Greater than 150" Greater than 200" Greater than 300" SPLAY ‘None Allowed ‘None Allowed Refer to iit samples BURNS . . er note exception in GAS MARKS . : Quality Plan MARBLING e : . ORANGE PEEL a : . NON-UNIFORM TEXTURE : : PITTING : a . CRACKING S . CRAZING * £ . DELAMINATION a : = COLD SLUGS ~ * : © 1994 The Society of the Plastics Industry, Ine Version A The Society of the Plastics Industry Cosmetic Specifications Part Name: Authorized by! Part Number: GRADE 3 - (Painted / Finished parts) SURFACE A B c SPECKS, DISCOLORATION, & GLOSSINESS ACCEPTIF- —Lessthan or equal Less than or equal Less than or equal {.010" Nocloser 10.015". Nocoser 10.015" than {inch ‘tan inch ALLOWABLE .010*-.020" 15". 040" 013°- 0868; RANGE, ‘Allow 2 per 16 inch?” “Allow 4 per 16 inch? “Allow 6 per 16 inch? (area, (8x4). Noose (8x4). Noclosr ‘han 2 inches, ‘than 1 inches. REJECTIF- Greater han 020", Greater than 040", (Greater than.050" SCRATCHES & LINT ACCEPTIF- 010"x.030 ot less L020" x 090" or less, (020'x $00" o less, ‘Allow 2 pe 16 inch? Allow 4 per 16 inc? Allow 4 pe 16 inet* (4Prx4")/Nocloserthan —(4"¥¢4").Noloserthan_——_(4" 4"), No closer than inh inch inet RRIRCTIF- Creator than O10 O31 Cavatnr than 020" x O50" Greate than 020 x 500", MARKS & RUNS ACCEPTIF: none 020° x.050"or less, 1020°x $00" oss Alle 2 per 16 neh? ‘Allow @ per 16 inch? ("x4"), Nocloser than (4"x4") Nooser than Vine Vine REJECT. sy found Gueatee chan 020° x.050" Greater than ,020"x.500” NON-ADHESION OR NON-UNIFORM COVERAGE ACCEPTIF= none. 125% or less 250 or less. ‘Allow 2 pee 16 fue? ‘tw yor 16 in? (4°49 Nocloserthan (4° 4"), No closer than Vine, Vin, KesCL I any found (Greater than 125) Greater than 2507 © 1994 The Society of the Plastics Industry, Ine. Version A The Society of the Plastics Industry Cosmetic Specifications Cutomer: Part Name Part Number Authorized by: ane GRADE 4 - (Decorated Parts - stamped, printed, silk screened, in-mold,... etc.)) al SURFACE, A B c

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