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Heating is 22 seconds of a 45 second cycle and no robot can touch it. Handling cost falls from 9.5 to 2.7 cents a part as cavities go from one to six with a robot, but at one cavity the robot is 11.0 cents against 9.5 for a person.
Density falls from 0.75 to 0.42 g/cm3 as blowing agent goes from 0.4 to 1.2 phr, and each 0.2 phr buys less than the one before. Thermal conductivity bottoms out at 0.45 g/cm3, so the lightest board is not the best insulator and not the cheapest wall.
Fill pressure falls from 62 to 44 MPa as speed rises from 10 to 50 mm/s, then climbs back to 68 at 150. The floor is where freezing stops choking the flow, not where the machine is happiest, and the profile has to follow the geometry.
Six tenths of a phr of internal release cuts demoulding force from 180 to 75 newtons. At 1.5 phr it cuts it to 30 and takes secondary bond strength to 30 percent of control. Most of the release is in the first third of the dose, and all of the damage is in the last third.
Eight degrees of nesting removes 57 percent of stack height for a hundred parts. It also puts 429 newtons on the bottom part of a fifty-high stack, and a 1.2 mm wall at 60 C creeps under that in a trailer. The angle is a cost decision with a failure mode attached.
Under D65 the sample measures 0.4 Delta E and passes. Under the shop’s LED the same part measures 2.9 and fails. Colour is a spectrum, not a number, and two percent of dosing error is already past the visible threshold.
A flat profile is what a machine ships with, not what a polymer needs. Rising protects the melt and costs nothing; falling mixes better and degrades more. A cold feed adds 60 percent to recovery time.
Shrink falls from 3.8 to 2.2 percent across a 40 phr change in filler, and flash from 0.35 to 0.03 mm across the clamp pressure range. The parting line is the one thing the tool cannot fix afterwards.
Forty-five percent of trim error comes from how the part is held, 30 from the part itself, 15 from the machine and 10 from the tool. A 200 N clamp deflects a 0.8 mm wall by 1.8 mm, which is twelve times the tolerance.
Cutting packaging spend in half doubles the scratch rejects, from 6 percent to 12. The optimum sits at 0.75 of standard spend, and overspending past it costs eight times more per metre than underspending does.
Shrinkage nearly doubles from 1.8 to 3.4 percent as the mould goes from 20 C to 100, and gloss goes from 18 to 66 units over the same range. One variable, two properties, and no way to set them independently.
Volatiles fall from 1.8 percent to 0.35 in four hours at 200 C, and compression set falls from 38 to 16 percent between no post-cure and 225 C. Past that, set climbs back to 20 and the cure is doing damage.
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