Plastic411: Plastic Injection Testing

Welcome to the Plastic411  Processing Assessment. Upon completion, this test is designed to identify plastic injection skill level. Skill range is from material handler to process engineer.

Thanks for using this platform, and feel free to contact me for help with training development onsite at your facility. Plastic411 training is floor intensive, taught only on the floor using your presses, equipment, materials, processes:

Garrett MacKenzie
Owner/ Editor


Question #1: What reasons below might lead to an erratic and inconsistent cushion?

Question #2: When installing clamps, the bolts should be torqued to:

Question #3: This burn defect is on every shot. The burn is occurring half way through the injection. If the part has a 10″ inch shot size, how should the injection be profiled?

Question #4: T or F: When changing a hot runner mold, hot runner can be heated to temperature 30 minutes prior to changing mold to reduce mold change time.

Question #5: Peak pressure is:

Question #6: Parts you are producing are too small according to print. What changes might you make to increase their dimensions?

Question #7: Gassing is common with many materials, such as nylon. How often should a mold be cleaned and checked for proper greasing?

Question #8: Color swirls can be caused by:

Question #9: When making a change to back pressure, how long does it take for barrel temperature to stabilize?

Question #10: A press keeps alarming because the metering zone temperature is higher than normal. The monitoring is set at 25 degrees above the setpoint. What reasons below could be causing it

Question #11: T or F: A part that is short (not completely filled) and has flash should be checked for signs of tool damage or wear at the parting line.

Question #12: The glass transition temperature (Tg) is:

Question #13: If this part was pulled from the mold with the side marked “warp” being the stationary half, what adjustment would you make to get rid of the warp (after you checked to make sure mold set up was correct)?

Question #14: A material that is hydroscopic is prone to drawing in moisture and must be dried at the temperature and time determined by the material manufacturer

Question #15: This part has signs of heavy splay at end of fill. Which of the following changes may improve the condition, or identify the cause?

Question #16: Which is the best method of ejector set up?

Question #17: When is it important to close a mold in set-up mode?

Question #18: When setting a mold, clamps should be attached:

Question #19: A gate seal study is performed to:

Question #20: Based on this gate seal chart, Hold time for this process should be:

Question #21: What conditions lead to bubble (void) defects in a part?

Question #22: True or False: A pressure drop study is best utilized when injection pressures are close to or at maximum pressure at middle to end of fill within the molding process

Question #23: When changing from nylon to polypropylene during a mold change:

Question #24: What is the purpose of a nylon tip?

Question #25: What is the drying time and temperature for Polypropylene?

Question #26: The flash pictured needs to be corrected using process changes. Choose answers below to correct condition.

Question #27: The purpose of Process Monitoring is:

Question #28: Shear heat from the screw rotation and back pressure supplies 70-90% of the total heat in the screw. Heater bands supply the rest and help prevent fluctuations.

Question #29: A burn at the flow front’s end of fill can be a sign of:

Question #30: Which of the following shows an example of a submarine gate?


Question #31: A press uses 85 pounds of material per hour, producing 170 parts. How much material will be used in 5 hours, and how many parts will be produced? How much does 1 part weigh?

Question #32: After confirming that melt temperature is in the middle of the melt window, what happens to material viscosity and fill time when heats are raised?

Question #33: The typical peak pressure for nylon is:

Question #34: If bar x is moved to the right, what direction will the gears move the bottom bar?

Question #35: The material manufacturer recommends a melt window of 500-550 F, and the melt temperature checks at 546. What result might you get if you increase back pressure?

Question #36: Runner size should be ____________ the wall thickness dimension of a part.

Question #37: Melt temperature is measured by:

Question #38: If a material ratio is identified at 25:1, or 4%.. the correct mixture would be:

Question #39: A dryer that is working properly, should:

Question #40: Where in the screw does the majority of plastic melting occur?

Question #41: What is the normal drying time and temperature for unfilled nylon?

Question #42: True or false: Size and shape of material from grinder does not affect how it mixes with virgin material or the production process.

Question #43: When making changes to back pressure, how long does it take for those changes to take effect?

Question #44: When venting a mold, what percentage of the cavity parameter should be vented and at what spacing?

Question #45: The orifice of a nozzle tip should be ________________ the sprue bushing orifice

Question #46: What steps are taken to develop a decoupled molding process?

Question #47: When making a change from injection to hold pressure (cut-off), how long does it take for the change to take effect in the process?


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