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Preface

This third edition has been written to thoroughly update the coverage of injection molding inthe World of Plastics. There have been changes, including extensive additions, to over 50of the content of the second edition. Many examples are provided of processing differentplastics and relating the results to critical factors, which range from product design to meetingperformance requirements to reducing costs to zero-defect targets. Changes have not beenmade that concern what is basic to injection molding. However, more basic information hasbeen added concerning present and future developments, resulting in the book being moreuseful for a long time to come. Detailed explanations and interpretationof individual subjectsmore than 1500) are provided, using a total of 914 figures and 209 tables. Throughout thebook there is extensive information on problems and solutions as well as extensive cross-referencing on its many different subjects.This book represents the ENCYCLOPEDIA on IM, as is evident from its extensive anddetailed text that follows from its lengthy Table of CONTENTS and INDEX with over5200 entries. The worldwide industry encompasses many hundreds of useful plastic-relatedcomputer programs. This book lists these programs ranging from operational training toproduct design to molding to marketing) and explains them briefly, but no program or seriesof programs can provide the details obtained and the extent of information contained in thissingle sourcebook.In the manufacture of molded products there is always a challenge to utilize advancedtechniques, such as understanding the different plastic melt flow behaviors, operational moni-toring and control systems, testing and quality control, and statistical analysis. However,these techniques are only helpful if the basic operations of molding are understood andcharacterized, to ensure the elimination or significant reduction of potential problems.The book provides an understanding that is concise, practical, and comprehensive and thatgoes from to Z on the complete subject of injection molding. It provides concise informationfor either the technical or the nontechnical reader, interrelating and understanding basicfactors starting with the plastics melt flow behavior during processing. It should be usefulto the fabricator, moldmaker, designer, engineer, maintenance person, accountant, plantmanager, testing and quality control worker, cost estimator, sales and marketing person,venture capitalist, buyer, vendor, educator/trainer, workshop leader, librarian/informationprovider, lawyer, consultant, and others. People with different interests can focus on andinterrelate across subjects that they have limited or no familiarity with in the World of Plastics.s explained throughout this book, this type of understanding is required in order to besuccessful in the design, prototyping, and manufacture of the many different marketablemolded products worldwide.

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refaceThe reader will have a useful reference for pertinent information readily available in the

table of contents and the index. As past book reviewers have commented, the informationcontained in this book is of value to even the most experienced designers and engineers, andprovides a firm basis for the beginner. The intent is to provide a complete review of all aspectsof the injection molding process that goes from the practical to the theoretical, and from theelementary to the advanced.This book can provide people not familiar with injection molding an understanding ofhow to fabricate products in order to obtain its benefits and advantages. It also providesinformation on the most common and costly pitfalls or problems that can develop, resultingin poor product performance or failures. Accompanying the problems are solutions. Thisbook will enhance the intuitive skills of those people who are already working in plastics. Itsemphasis is on providing a guide to understanding the worldwide technology and business ofinjection-molded products.

From a pragmatic standpoint, every theoretical aspect that is presented has been expressedso that it is comprehensive and useful. The theorist, for example, will gain insight into thelimitations of plastics relative to other materials such as steel and wood. After over a centuryof worldwide production of all kinds of injection-molded products, they can be processedsuccessfully,yielding high quality, consistency, and profitability.As described in this book, onecan apply the correct performance factors basedon an intelligent understanding of the subject.

This book has been prepared with the awareness that its usefulness will depend on itssimplicity and its ability to provide essential information. With the experience gained inworking in the injection molding industry worldwide and in preparing the first and secondeditions as well as other books, we believe that we have succeeded in that purpose and haveprovided a useful, practical reference work.

The injection molding industry consumes about 3 wt of all plastics. The plastics industryas a whole is ranked as the fourth largest industry in the United States. With plastics, toa greater extent than other materials, opportunity for improvement will always exist, sincenew and useful developments in materials and processing continually are on the horizon.Examples of these developments are given in this book, providing guides to future trends inthe world of plastics.

The limited data presented on the properties of plastics are provided as comparative guides;readers can obtain the latest information from material suppliers, industry software, and/orsources mentioned in this books reference section. Our focus in the book is to present,interpret, analyze, and interrelate the basic elements of injection molding for processingplastic products. As explained in this book, there are over 17,000plastic materials worldwide,and selecting the right one requires specifyingall product performance requirements, properlysetting up and controlling the injection molding process to be used, and intelligently preparinga material specification purchase document and work order to produce the product.

The many properties of different plastics are important for different purposes. Some meethigh performance requirements such as long-time creep resistance, fatigue endurance, ortoughness. On the other hand, for some plastics, ready supply and low cost are the main ad-vantages. As explained in this book, each of the different materials requires specific injectionmolding operating procedures.

Patents or trademarks may cover some of the information presented. No authorizationto utilize these patents or trademarks is given or implied; they are discussed for informa-tion purposes only. The use of general descriptive names, proprietary names, trade names,commercial designations or the like does not in any way imply that they may be used ascommon nouns. While the information presented is believed to be true and accurate, neitherthe authors nor the publisher can accept any legal responsibility for any errors, omissions,inaccuracies, or other factors.

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reface xxxiIn preparing this book and ensuring its completeness and the correctness of the subjects

reviewed, use was made of the authors worldwide personal, industrial, and teaching expe-rience that totals over a century, s well as worldwide information from industry (personalcontacts, conferences, books, articles, etc.) and trade associations.

THEROS TOS