A cost effective filling control device was designed,prototyped,and evaluated in an attempt to reduce variation in the quality of injection molded parts.The patent pending method consists of an internal switch that is actuated by the melt flow in the cavity.A four run full factorial DOE was carried out for each of the V/P transfer methods that were compared:screw position,cavity pressure,mold surface temperature,and the new in-mold switch (MeltSwitch~TM).The part weight was measured to determine how each method was affected by viscosity and decompression variation.It was found that the mold surface temperature and MeltSwitch~TM performed the best in minimizing part weight variation.
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