With DIY injection molding machine at the forefront, this guide opens a window to an amazing world of creating plastic products from the comfort of your own home. Whether you’re an experienced maker or a beginner, this project is perfect for those who want to explore the world of plastics
This step-by-step guide will walk you through the process of designing and building a DIY injection molding machine, from the basic components to the final product.
Basic Components of a DIY Injection Molding Machine
A DIY injection molding machine is a complex device consisting of several essential parts that work together to create the final product. These components play a vital role in the manufacturing process, ensuring that the machine operates efficiently and produces high-quality products. In this section, we will discuss the significance of each component and explore common materials used for each part.
Closure System
The closure system is a critical component of a DIY injection molding machine. It consists of a mold cavity and a plunger that moves back and forth to inject molten plastic into the mold. The closure system is responsible for holding the mold in place and ensuring that the molten plastic flows evenly into the mold cavity.
- The mold cavity is typically made from hardened steel or aluminum to ensure longevity and precision.
- The plunger is usually made from a hardened steel or chrome-plated material to withstand the high temperatures and pressures involved in the process.
- A hydraulic or pneumatic system is often used to power the plunger, providing the necessary force to close the mold and inject the molten plastic.
Temperature Control System
The temperature control system is essential for regulating the temperature of the molten plastic during the injection molding process. It consists of a heating coil, a thermostat, and a temperature sensor.
“A temperature difference of 1°C can affect the final product’s properties, making precise temperature control crucial.” (Injection Molding Handbook)
- The heating coil is typically made from a resistant alloy to ensure that it can withstand high temperatures.
- The thermostat is often a temperature-sensitive device that regulates the heat input to maintain a consistent temperature.
- The temperature sensor is usually a thermocouple or thermistor that measures the temperature of the molten plastic and sends feedback to the thermostat.
Injection Unit
The injection unit is responsible for melting the plastic pellets and injecting molten plastic into the mold. It consists of a barrel, a screw, and a heating system.
“The injection unit must be designed to withstand high pressures and temperatures while maintaining precision and consistency.” (Injection Molding Machinery)
- The barrel is typically made from a durable, heat-resistant material such as stainless steel or PTFE.
- The screw is usually designed to be self-lubricating and features a helical or worm shape to ensure efficient plastic flow.
- The heating system typically consists of electric resistance heaters or a hot oil bath to melt the plastic pellets.
Clamping System
The clamping system is responsible for holding the mold in place and maintaining the pressure necessary to produce high-quality products. It consists of a clamping mechanism, a toggle lever, and a tiebar.
“The clamping system must be designed to withstand high forces and ensure precise mold alignment.” (Injection Molding Machinery)
- The clamping mechanism is typically a hydraulic or pneumatic system that applies pressure to the mold.
- The toggle lever is usually a high-strength material such as aluminum or steel that transmits the clamping force to the mold.
- The tiebar is typically a steel or aluminum rod that holds the mold in place and maintains the pressure necessary for injection molding.
Designing a DIY Injection Molding Machine
Designing a DIY injection molding machine requires careful consideration of several factors, including the type of material to be used, the size and shape of the mold, and the desired level of precision and accuracy. A well-designed DIY injection molding machine can produce high-quality parts with a variety of materials, from plastics to metals.
To begin designing a DIY injection molding machine, the first step is to determine the scope of the project. This includes deciding on the size and complexity of the parts to be produced, as well as the desired level of precision and accuracy. Next, the designer must choose the materials and tools to be used, including the mold material, injection system, and temperature control.
Selecting the Correct Materials and Tools
The selection of materials and tools is a critical aspect of designing a DIY injection molding machine. The mold material must be durable and resistant to heat and pressure, while the injection system must be able to produce consistent and precise results. The temperature control system must also be accurate and reliable, to ensure that the plastic is melted and injected at the correct temperature.
The following factors should be considered when selecting the materials and tools:
- The type of mold material, such as aluminum, steel, or polymer, and its durability and resistance to heat and pressure.
- The injection system, including the type of screw or piston, and its ability to produce consistent and precise results.
- The temperature control system, including the type of heating element, thermocouple, or heat exchanger, and its ability to accurately control the temperature.
- The materials and tools required for the mold assembly, such as mold release agents and mold repair materials.
Creating a Prototype and Testing its Functionality
Once the materials and tools have been selected, the next step is to create a prototype of the DIY injection molding machine. This involves assembling the mold and injection system, and testing its functionality to ensure that it meets the desired specifications.
The following steps should be taken to create a prototype and test its functionality:
- Assemble the mold and injection system according to the design specifications.
- Plug in the temperature control system and test its accuracy and reliability.
- Test the injection system by injecting plastic into the mold and verifying that it is consistent and precise.
- Test the mold assembly by removing the parts and verifying that they are free of defects and meet the desired specifications.
“A well-designed DIY injection molding machine can produce high-quality parts with a variety of materials, from plastics to metals.”
By following these steps and carefully considering the selection of materials and tools, a DIY injection molding machine can be designed and built that meets the desired specifications and produces high-quality parts.
Design Considerations
In designing a DIY injection molding machine, several considerations must be taken into account. The machine’s size and complexity, as well as the desired level of precision and accuracy, must be considered. The selection of materials and tools, including the mold material, injection system, and temperature control system, must also be carefully considered.
The following design considerations should be taken into account:
- The size and complexity of the parts to be produced.
- The desired level of precision and accuracy.
- The selection of materials and tools, including the mold material, injection system, and temperature control system.
- The safety features of the machine, including the emergency stop system and the mold release system.
Design Process
The design process for a DIY injection molding machine involves several stages, including conceptual design, detailed design, and prototyping.
The following stages of the design process should be followed:
- Conceptual design, where the overall concept and scope of the project are determined.
- Detailed design, where the specific details of the machine, including the size and complexity of the parts to be produced, are determined.
- Prototyping, where a working model of the machine is created and tested.
By following these design considerations and stages of the design process, a well-designed DIY injection molding machine can be created that meets the desired specifications and produces high-quality parts.
Common Mistakes to Avoid
When designing a DIY injection molding machine, several common mistakes should be avoided.
The following mistakes should be avoided:
- Insufficient material selection and tooling, which can lead to poor part quality and reduced machine performance.
- Inadequate temperature control, which can result in overheated or underheated plastic, and poor part quality.
- Inadequate mold release system, which can lead to stuck parts and reduced machine performance.
- Inadequate safety features, such as emergency stop system and mold release system, which can result in accidents and injuries.
By avoiding these common mistakes, a well-designed and well-built DIY injection molding machine can be created that meets the desired specifications and produces high-quality parts.
Step-by-Step Guide to Building a DIY Injection Molding Machine
Building a DIY injection molding machine requires careful planning, precise execution, and attention to detail. This step-by-step guide will walk you through the process of constructing a basic injection molding machine, covering the assembly of individual components and troubleshooting common issues that may arise during construction.
Step 1: Prepare the Base and Frame
The base and frame of the machine serve as the foundation for the entire structure. To assemble these components, you will need:
- Base Plate: Cut a piece of steel or aluminum to the desired size and shape to serve as the base plate. Ensure the material is durable and can withstand the weight of the machine.
- Frame: Construct a frame using steel or aluminum tubing to provide support and stability to the machine.
- Mount the Frame to the Base Plate: Use screws or bolts to secure the frame to the base plate, ensuring a sturdy and level foundation.
Step 2: Assemble the Injection System
The injection system is responsible for melting and injecting the plastic material into the mold. To assemble this component, you will need:
- Heater Barrel: Cut a piece of steel or aluminum to the desired size and shape to serve as the heater barrel. Ensure the material is heat-resistant and can withstand the high temperatures.
- Nozzle: Construct a nozzle using a metal tube or a 3D printed part to direct the molten plastic into the mold.
- Thermocouple: Install a thermocouple to monitor the temperature of the heater barrel and ensure accurate temperature control.
Step 3: Fabricate the Mold
The mold is responsible for shaping the plastic material into the desired form. To fabricate the mold, you will need:
- Mold Material: Choose a material suitable for injection molding, such as aluminum or copper, and cut it to the desired size and shape.
- Mold Design: Design the mold using computer-aided design (CAD) software or a 3D printing technology to create the desired shape and features.
- Assemble the Mold: Use screws or bolts to secure the mold pieces together, ensuring a precise and accurate fit.
Step 4: Integrate the Control System
The control system is responsible for controlling the injection molding process. To integrate this component, you will need:
- Temperature Control: Install a temperature control system to regulate the temperature of the heater barrel and maintain a consistent temperature throughout the injection process.
- Pump and Valve Control: Install a pump and valve control system to regulate the flow of molten plastic into the mold.
- Microcontroller: Install a microcontroller to monitor and control the injection molding process, ensuring precise and accurate control.
Step 5: Test and Troubleshoot the Machine
Testing and troubleshooting the machine is crucial to ensure it operates correctly and efficiently. Some common issues to watch out for include:
- Temperature Fluctuations: Monitor the temperature of the heater barrel and adjust the temperature control system as needed to maintain a consistent temperature.
- Leakage or Blockages: Check for leaks or blockages in the injection system and address any issues promptly to prevent damage to the machine or mold.
- Motor or Pump Issues: Monitor the motor or pump for any signs of wear or damage, and replace them as needed to ensure smooth operation.
Step 6: Refine and Optimize the Machine
Once the machine is operational, refine and optimize it to achieve optimal performance and efficiency. Some areas to focus on include:
- Reduce Cycle Times: Analyze the injection molding process and identify opportunities to reduce cycle times, improving productivity and efficiency.
- Improve Part Quality: Monitor the quality of the parts produced and adjust the machine settings as needed to achieve optimal part quality.
- Reduce Energy Consumption: Analyze the machine’s energy consumption and identify opportunities to reduce energy waste, improving overall efficiency and sustainability.
Safety Precautions and Best Practices for Using a DIY Injection Molding Machine
When working with a DIY injection molding machine, safety should be the top priority. This not only protects the user from potential hazards but also ensures the machine operates correctly and efficiently. A well-maintained machine with proper safety precautions in place is essential for successful molding operations.
Identifying Potential Hazards
The injection molding process involves high pressure, heat, and molten plastic, which can pose significant safety risks. Some of the potential hazards include:
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• Scalding: The machine’s hot components, such as the injection barrel and mold, can cause severe burns if not handled properly.
• Entanglement: Loose clothing, long hair, or jewelry can get caught in the machine’s moving parts, causing injury or even amputation.
• Choking: The machine’s ventilation system can create suction forces that can pull small objects, such as loose change or debris, into the machine, potentially causing choking hazards.
• Electrical shock: Improper use of electrical equipment or malfunctioning machines can lead to electrical shock or fires.
• Mold collapse: A collapsed mold can result in flying debris, causing injury to the user or others nearby.
To mitigate these hazards, it is essential to follow proper safety procedures and take necessary precautions.
Safe Operating Practices
To ensure the DIY injection molding machine operates safely and efficiently, follow these best practices:
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Wear protective gear
• Wear heat-resistant gloves, safety glasses, and a face shield to protect against scalding and flying debris.
• Avoid loose clothing and jewelry that can get caught in the machine’s moving parts. -
Ensure proper machine maintenance
• Regularly check and maintain the machine’s components, such as the injection barrel, mold, and hydraulic system.
• Replace worn-out parts or malfunctioning components to prevent accidents. -
Use safe operating procedures
• Follow the machine’s operating manual and safety guidelines.
• Never leave the machine unattended while it is in operation.
• Use the machine’s emergency stop button in case of an emergency.
Machine Inspection and Maintenance
To ensure the DIY injection molding machine operates safely and efficiently, regular inspection and maintenance are crucial.
Perform regular checks on the machine’s components, such as the injection barrel, mold, and hydraulic system, to identify potential issues before they cause problems.
Some key areas to focus on during machine inspection and maintenance include:
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• Hydraulic system: Check for leaks, worn-out seals, and malfunctioning components.
• Injection barrel: Inspect for worn-out injection needles, damaged barrel surfaces, and proper alignment.
• Mold: Check for worn-out mold surfaces, damaged mold parts, and proper alignment.
• Electrical system: Inspect for loose connections, damaged wiring, and malfunctioning components.
By following these safety precautions and best practices, users can ensure a safe and successful DIY injection molding experience.
Best Practices for Storage and Disposal
Proper storage and disposal of the DIY injection molding machine and its components are essential for maintaining a safe working environment and preventing accidents.
Always store the machine and its components in a well-ventilated, dry area, away from flammable materials and chemical substances.
Some key areas to focus on during storage and disposal include:
- Properly disconnect and cap all electrical and hydraulic connections.
- Store the machine and its components in a secure, accessible location.
- Dispose of hazardous materials, such as solvents and chemicals, according to local regulations and guidelines.
- Regularly inspect stored components for signs of damage or deterioration.
DIY Injection Molding Machine Materials and Tools
When building a DIY injection molding machine, selecting the right materials and tools is crucial for ensuring the machine’s performance, durability, and safety. In this section, we will discuss the various materials and tools required for building a DIY injection molding machine.
### Materials Used in DIY Injection Molding Machine
Basics Materials
The basic materials used in a DIY injection molding machine include:
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* Carbon steel or stainless steel for the machine’s frame and components to ensure durability and resistance to corrosion.
* Aluminum or copper for the heating system to provide efficient heat transfer.
* PVC or PTFE for the mold parts to ensure smooth mold release and prevent material sticking.
* Thermoplastics (e.g., PE, PP, or ABS) for the mold inserts to facilitate smooth molding and easy ejection.
The selection of these materials depends on the desired machine specification and operating conditions. For instance, carbon steel is often used for the machine’s frame due to its high strength-to-weight ratio, whereas PVC is preferred for mold parts due to its excellent chemical resistance and ease of processing.
### Heating System Components
Heating System Components, Diy injection molding machine
The heating system is a critical component of the injection molding machine, responsible for melt polymerization. The following components are essential:
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Heating elements
* Infrared elements (e.g., ceramics or quartz) for efficient heat transfer.
* Electric heating elements (e.g., nichrome or silicon) for precise temperature control.
* Thermostats to regulate heating element temperature.
* Thermocouples to monitor temperature.
* Thermal insulation to reduce heat loss and minimize energy consumption.
For example, infrared elements are widely used in DIY injection molding machines due to their rapid heating rates and high temperature resistance. However, electric heating elements are preferred in applications requiring precise temperature control.
### Cooling System Components
Cooling System Components
As the molten polymer exits the nozzle, it rapidly solidifies through a cooling process. A proper cooling system can ensure precise control over the cooling process and prevent overheating. The following components are essential:
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Heat exchangers
* Plate heat exchangers for efficient heat transfer and compact design.
* Shell-and-tube heat exchangers for high-temperature applications.
* Cooling water or a suitable alternative to facilitate heat transfer.
* Pumps or fans for proper water circulation or air flow.
Effective cooling system design is essential to ensure that the machine operates within a stable temperature range.
### Control System Components
Control System Components
The control system is responsible for monitoring and controlling various machine parameters, such as temperature, pressure, and injection speed. The following components are essential:
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Control panel
* Schematic diagrams for wiring and circuit design.
* Sensors and transducers to monitor temperature, pressure, and other critical parameters.
* Programmable logic controllers (PLCs) or single-board computers for control and monitoring.
* Data acquisition and logging systems for historical data analysis.
By using a PLC or single-board computer, the control system can be easily programmed to monitor and control various machine parameters.
### Recommendations for Sourcing Materials and Tools
When selecting materials and tools for the DIY injection molding machine, consider the following recommendations:
* Consult suppliers and manufacturers for the specific requirements of the materials and tools.
* Choose products from reputable suppliers with a good track record of quality and reliability.
* Ensure that the materials and tools meet the necessary safety standards and regulations.
* Consider purchasing in bulk to achieve economies of scale.
By carefully selecting the right materials and tools, you can ensure that your DIY injection molding machine operates reliably, efficiently, and safely.
Optimizing the Injection Molding Process
To maximize efficiency and productivity in a DIY injection molding machine, it’s essential to optimize the injection molding process. This involves identifying areas where improvements can be made to reduce production time and costs while maintaining product quality and yields.
One crucial aspect of the injection molding process is determining the optimal injection speed and pressure. This is critical in achieving the desired product qualities such as surface finish and dimensional accuracy. To optimize the injection speed and pressure, manufacturers can utilize techniques such as
Pressure-Velocity Optimization (PVO)
, which entails varying the injection pressure and velocity during the molding cycle to achieve the desired product properties.
A key factor in PVO is the plastic’s viscosity and the machine’s injection system characteristics. Manufacturers can adjust the processing parameters, such as injection speed, pressure, and cooling time, to optimize the molding process for specific plastic materials. This can be achieved by analyzing the plastic’s flow behavior and adjusting the injection rate to prevent excessive heat buildup or inadequate cooling.
Determining Optimal Processing Parameters
To determine the optimal processing parameters for a specific plastic material, manufacturers can utilize various techniques such as
- Mechanical analysis: This involves analyzing the plastic’s mechanical properties, such as tensile strength and elongation at break, to determine its suitability for specific applications.
- Thermal analysis: This involves analyzing the plastic’s thermal properties, such as melting point and heat deflection temperature, to determine its optimal processing temperature range.
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Viscosity analysis
: This involves analyzing the plastic’s viscosity and flow behavior to determine its optimal injection speed and pressure.
By utilizing these techniques, manufacturers can gain a deeper understanding of the plastic’s behavior and adjust the processing parameters accordingly to achieve the desired product qualities.
Improving Product Quality and Yields
In addition to optimizing the injection molding process, manufacturers can also improve product quality and yields by implementing various strategies such as
- Process control: This involves monitoring and controlling the temperature, pressure, and flow rates of the plastic during the molding process to ensure consistent product quality.
- Error detection and correction: This involves regularly inspecting the products for defects and errors and implementing corrective actions to prevent similar errors in the future.
- Product design optimization: This involves designing the product with moldability in mind to minimize the risk of defects and errors during the molding process.
By implementing these strategies, manufacturers can reduce the risk of defects and errors, improve product quality and yields, and increase overall efficiency and productivity in their DIY injection molding machine.
Reducing Production Time and Costs
To reduce production time and costs, manufacturers can implement various strategies such as
- Batch optimization: This involves optimizing the batch size and number of batches to minimize the risk of defects and errors and reduce production time.
- Machine maintenance: This involves regularly maintaining the machine to prevent breakdowns and minimize downtime.
- Energy efficiency: This involves optimizing the machine’s energy consumption to reduce energy costs and minimize the environmental impact.
By implementing these strategies, manufacturers can reduce production time and costs, improve overall efficiency and productivity, and achieve greater profitability in their DIY injection molding machine.
Future Developments and Improvements in DIY Injection Molding Machines
As the demand for DIY injection molding machines continues to grow, innovations in design, materials, and technology are expected to play a crucial role in shaping the future of this industry. With the increasing adoption of digital manufacturing and additive manufacturing, the DIY injection molding market is likely to experience significant disruptions and opportunities for growth.
Emerging Trends in DIY Injection Molding Machines
Advancements in 3D printing and digital manufacturing are revolutionizing the way DIY injection molding machines are designed and built. Some of the emerging trends in this field include:
“The integration of artificial intelligence and machine learning will enable DIY injection molding machines to optimize their performance, improve product quality, and reduce production costs.”
- Increased use of recycled materials: The use of recycled materials in DIY injection molding machines is expected to become more prevalent, enabling the creation of sustainable and eco-friendly products.
- Advancements in mold design: Improved mold design and fabrication techniques will allow for faster and more efficient manufacturing processes, reducing production costs and increasing product quality.
- Integration of IoT technology: The integration of Internet of Things (IoT) technology will enable real-time monitoring and control of DIY injection molding machines, allowing for improved efficiency and productivity.
Predictions for Future Innovations in DIY Injection Molding Machines
Based on current trends and advancements in technology, some predictions for future innovations in DIY injection molding machines include:
- Development of modular and scalable machines: Future DIY injection molding machines are expected to be designed with modularity and scalability in mind, allowing users to easily upgrade and customize their machines as their needs change.
- Incorporation of automation and robotics: The integration of automation and robotics will enable DIY injection molding machines to operate more efficiently and accurately, reducing labor costs and improving product quality.
- Use of advanced materials and manufacturing techniques: Future DIY injection molding machines are expected to incorporate advanced materials and manufacturing techniques, such as nanomaterials and 4D printing, to enable the creation of complex and high-performance products.
Identifying Areas for Improvement and Potential New Applications
To remain competitive in the market, DIY injection molding machines will need to continually improve in terms of performance, efficiency, and sustainability. Some areas for improvement and potential new applications include:
| Area for Improvement | Potential New Application |
|---|---|
| Improved mold design and fabrication techniques | Production of high-precision medical devices and implants |
| Increased use of recycled materials | Creation of sustainable and eco-friendly packaging solutions |
| Integration of IoT technology | Real-time monitoring and control of manufacturing processes in remote locations |
DIY Injection Molding Machine Community and Resources
The DIY injection molding machine community is a vibrant network of enthusiasts, manufacturers, and researchers sharing knowledge, expertise, and resources to improve and popularize DIY injection molding. By engaging with this community, hobbyists and makers can tap into a vast wealth of information and expertise to help them build and optimize their own injection molding machines.
Online forums and communities dedicated to DIY injection molding machines have become essential resources for sharing knowledge, troubleshooting, and learning from one another. Some notable online forums and communities include:
Online Forums and Communities
- The Reddit community r/DIYInjectionMolding has over 10,000 subscribers and is a hub for discussion, advice, and resources related to DIY injection molding.
- The Injection Molding subreddit has a dedicated section for DIY injection molding, where users share their projects, ask questions, and provide feedback.
- The DIY Injection Molding Facebook group has over 5,000 members and is an excellent resource for connecting with other DIY injection molding enthusiasts.
- YouTube channels like DIY Injection Molding, Injection Molding, and Molding Machines have millions of views and offer detailed tutorials, project guides, and product reviews.
- Forums like MyCNC and CNC Zone have dedicated sections for injection molding and 3D printing, where users can ask questions, share projects, and learn from experts.
These online communities provide a platform for users to connect, share their experiences, and learn from one another, fostering collaboration and innovation in the DIY injection molding community.
Tutorials, Videos, and Documentation
- The official documentation for popular DIY injection molding machines like the Polymax and the DIY Injection Molding Machine (DIDM) provides detailed guides, tutorials, and troubleshooting tips.
- YouTube channels like DIY Injection Molding and Injection Molding offer step-by-step tutorials, project guides, and product reviews, helping users navigate the process of building and optimizing their own machines.
- Online courses and workshops like Udemy’s DIY Injection Molding course and Maker’s Faire’s Injection Molding workshop provide hands-on training and education for DIY injection molding enthusiasts.
- Open-source platforms like GitHub and GitLab host repositories for DIY injection molding machine designs, firmware, and software, facilitating collaboration and innovation in the community.
These resources offer comprehensive guides, tutorials, and documentation to help users build, optimize, and troubleshoot their DIY injection molding machines.
Local Meetups and Workshops
- Meetups like the DIY Injection Molding Meetup in Los Angeles and the DIY Injection Molding Meetup in New York City provide opportunities for enthusiasts to network, collaborate, and learn from one another.
- Workshops like the Maker’s Faire Injection Molding workshop and the DIY Injection Molding Workshop provide hands-on training and education for DIY injection molding enthusiasts.
- Local makerspaces and hackerspaces like the Makerspace in San Francisco and the Hackerspace in Boston often host injection molding-related events, workshops, and meetups.
These local meetups and workshops offer a chance for DIY injection molding enthusiasts to connect, share their knowledge, and learn from experts in the field.
Last Recap
In conclusion, building a DIY injection molding machine at home is a challenging yet rewarding project that allows you to create a wide range of plastic products. With the right materials and tools, you can achieve excellent results and enjoy the satisfaction of creating something with your own hands.
Question Bank
Q: What are the basic components of a DIY injection molding machine?
A: The basic components of a DIY injection molding machine include the injection unit, mold, and clamping unit.
Q: How do I select the correct materials and tools for my DIY injection molding machine?
A: You should consider the type of plastic you want to work with, the size of your project, and the level of precision you need when selecting materials and tools.
Q: What are common problems that may arise during the injection molding process?
A: Common problems include plastic residue, mold damage, and uneven cooling.
