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Gas-assist injection molding is a relatively new process. It is an extension of conventional injection molding and allows molders to make larger parts having projected areas or cross sectional geometries not previously possible using existing equipment. However, controlling the injection of the gas has been a concern. The plastics industry is attempting to establish logical techniques to set up and rationalize processing conditions for the method. Although gas injection equipment permits a number of adjustments, an optimum processing window must be established to provide control and repeatability of the process to mold consistent, acceptable parts. This paper describes a strategy and equipment for rationalizing and accurately controlling gas injection processing conditions that are applicable regardless of the type of molding machine or processing license a molder is using.

The gas injection molding process created a great deal of interest when it was first introduced, especially on the part of the automotive plastics industry. The process allows injection molders to make larger parts with increased rigidity at lower clamping pressures. This, in turn, allows parts to be molded that have not previously been able to be created. However, the process has been hampered by problems. First and foremost have been the numerous patent infringement suits and licensing difficulties that have retarded the spread of the technology in the United States. Second, technological problems - such as controlling the seemingly erratic nature of the gas - have also been an issue. As with any new molding technology, the plastics industry is still attempting to establish logical techniques to set up and rationalize processing conditions for the method.