The basis for making consistent parts for customers is identifying where the physics and chemistry of plastics processing come together- inside of the mold cavity. This is where the PVT relationships occur. To make consistent parts, the PVT relationships from cavity to cavity must be consistent. Cavity pressure, or the "P", is the best signal for process optimization. However, cavity pressure is only part of the story. Coupled with cavity temperature, or "T", the location of the melt front is ascertained directly. Case studies and examples of closed loop process control applications based upon melt front detection will be presented. Some applications to be covered are gas assist, sequential molds, multi-component molds, LSR, automatic transfer to holding pressure, as well as many others.
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