Scientific Mold Validation

The purpose of the validation is to identify a capable mould-process combination, which will achieve required part dimensions and tolerances consistently and repeatedly.

A mould-processing window is set during qualification to assure the quality of parts before they are actually manufactured and supplied to the customer.

We provide a complete qualification report with the mold manual outlining process and installation parameters.

Main steps of process validation are,

  • Process stability test
    • Purpose: Identify gross mechanical design/construction defects, which can cause part variation over time.
    • Output: Ensure that Mould is free of any mechanical defect to avoid short shot, flash, blemishes, scratches, water leakage, voids, etc.
  • Mould viscosity test
    • Purpose: Identify the maximum and minimum fill rates allowed for the mould with a specific plastic material.
    • Output: Best Mould fill rate (& viscosity) & Peak injection pressure for particular mould, machine, material.
  • Balance of fill Analysis
    • Purpose: Evaluate thermal and flow balance of the plastics melt distribution system in the mould.
    • Output: Mould feed system is well balanced and process parameter effect on each cavity will not vary more than 5%. This ensures better process window.
  • Gate seal teat
    • Purpose: Identify hold conditions to freeze the gate and thus correct part weight, and hold parameters.
    • Output: Right Hold time and pressure with correct part weight.
  • Multi cavity analysis
    • Purpose: To Ensure all cavities in the mould deliver the same quality. No difference between cavities for CTQ (critical to quality) dimensions.
    • Output: All cavities of mould is capable to deliver CTQ dimension within specific range
  • Process capability study (SPC)
    • Purpose: To ensure the process can meet the specified CTQ tolerance ranges.
    • Output: The process is capable to deliver parts within specified tolerance consistently.
  • Process centring
    • Purpose: To ensure that the capable process spread is near centre (target) and meet the specified CTQ tolerance ranges.
    • Output: The process is capable to deliver parts within specified tolerance consistently over period of time.