GAS-ASSISTED INJECTION MOLDING OF HIGH GLOSS LARGE PARTS
Cruz, Miguel*, Trejo, Adalberto†
Grupo Celanese, S. de R. L. de C.V.*, Industria KI de México, S.A. de C.V.†
Av. Insurgentes Sur, 2453-201, Col. Tizapán San Angel, C.P. 01090, Del. Alvaro Obregón, México.
Teléfono: (55) 54-80-94-23.
E – mail: mcruz@celanese.com.mx,
RESUMEN
El proceso de inyección asistida por gas, permite la
fabricación de piezas largas de sección transversal
gruesa. En piezas de apariencia, el nivel de brillo es
un requerimiento importante en sectores de mercado,
tales como el de electrodomésticos. Nuevos
materiales plásticos se han desarrollado con el fin de
incrementar el brillo y poder alcanzar la apariencia
deseada en un producto al salir del molde. Este
artículo explora resinas de poliéster como una manera
de conseguir alto brillo en piezas largas y como una
posible alternativa de sustitución de resinas
termofijas, trayendo consigo ahorros en material y
tiempo de ciclo.
ABSTRACT
Gas assist injection molding allows for the production
of long rod-shaped parts with thick cross sections. On
aesthetic parts, a high gloss level is a main
requirement in some markets, like appliances. New
plastic materials have been developed for increasing
the gloss level and to achieve the desired appearance
right out of the mold. This paper exposes polyester
resins as a way to get high gloss in smooth large
parts, which are commonly used in oven handles.
INTRODUCTION
Gas assist injection molding (GAIM) is a method of
pressurizing an injection molded part with gas, via a
network of flow channels, or directly into a part, to
provide the necessary packing force to produce a
quality injected molded product [1]. The gas is used
to form a hollow cavity inside the part.
The steps used to produce parts with gas assist
injection molding are: the mold closes, a precise shot
of resin is injected, the screw is usually bottomed out,
pressurized gas (usually N2) is introduced into the
melt of a partly pre-filled cavity at a certain delay
time, the screw returns for the next shot, gas pressure
is held in the part for the entire cooling phase, gas is
vented form the part, the mold is opened, and the part
is removed.
There are three main categories of molded parts,
which are especially appropriate for the production of
gas assisted injection molded parts [2]. The first
category includes tube or rod-shaped parts. Typical
parts for this category are handles and clutches. The
second category consists of large cover-shaped
structural parts with a network of gas channels often
combined with the rib structure of the parts.
Examples are automotive panels and business
machine covers. The third category covers complex
parts with thin and thick wall sections, where the
process is used for part integration by consolidating
several assembled parts into a single design. Tube or
rod-shaped parts have a one dimensional flow path
and the part effectively is the gas channel. The wall
thickness is a function of viscosity and temperature
distribution within the melt when nitrogen gas is
injected. Changes in polymer viscosity, temperature,
or gas pressure may play havoc on wall uniformity,
so a close watch on these variables is imperative [3].
In the mid 1990s, one-piece gas assist textured
handles replaced a three-piece plastic and metal
handles. Gas assist was chosen to consolidate parts,
minimize material and weight, and reduce cost. The
weight of a handle dropped by 45-55%. A decade
later, a glossy thermoplastic handle for the range
industry was developed. The molded parts had better
surface aesthetics, even though the oven handle was a
high flexural modulus, glass-reinforced PBT/PET
blend [3].
This provided Appliance Manufacturers a cost
effective alternative to thermoset plastic and painted
metal handles for oven doors [4]. A standard oven
handle is 760 mm long with a 30 mm by 20 mm
cross-section (30 inches by 1.25 inches by 0.75
inches). It is considered to be a large part in gas
assisted injection molding.
The gloss on the aesthetic side of a large cover-
shaped parts injected with gas assist injection
molding has been studied [5]. The gloss in large rod-
shaped parts has not been examined because the
shape and size of the part do not permit to measure it,
or it is very difficult to do so, and for those reasons
just visual evaluations are performed.
OBJECTIVE
The objective of this paper is to investigate the gloss
level in gas assisted injection molding large rod-
shaped parts. The gloss measurement study examines
a new polyester blend consisting of switching PET
and BMC in applications with high gloss like oven
handles.
GLOSS
Gloss is an optical phenomenon observed when
examining the appearance of a surface. The
evaluation of gloss is equal to the capability of a
surface to reflect directed light. Gloss is often used as
a criterion to evaluate appearance applications,
especially in the case of aesthetic products such as
appliances in which the OEMs requires high gloss,
but in the case the automotive industry, the low gloss
appearance is the trend. Measuring instruments,
figure 1, have been used to associate reflection
behavior and to define measurement values under
certain conditions. A visual gloss examination
includes many subjective sources of error and is not
sufficient when making comparisons in order to select
the best material or process for a specific part.
Therefore, to be objective, it is necessary to put a
measured value on the amount of gloss.
The measurement of the reflectometer is a relative
measurement compared to a highly polished black
glass with a refractive index of 1.567. The glass has
an assigned specular gloss of 100 for each
illumination angle considered: 20°, 60° or 85°. Since
instrument and standard tolerances are tightly
controlled, the measurement error should not be more
than +/- 1 unit.
HOW TO GET HIGH GLOSS
There are typically three ways to achieve a high gloss
appearance: (1) modify the surface of the mold to
high gloss, (2) modify processing parameters to
increase gloss, or (3) develop a material which is
inherently high gloss right out of the mold.
The tool surface can be polished to achieve a high
gloss finish on the steel which is transferred to the
plastic during molding, figure 2. Sometimes relying
strictly on mold texture is generally ineffective and
costly (tool maintenance) to meet the high gloss
requirements, but it is important in order to get the
desired gloss.
In case of processing parameters, raising mold
temperature increases the gloss in unfilled resins, but
in the case of glass fiber reinforced resins, the holding
pressure is important too. In gas assist injection
molding the mold temperature and gas packing
pressure are the key factors in order to have high
gloss in the part when the material is glass fiber
reinforced, figure 3. The disadvantage of raising mold
temperature is that cooling time is longer and the cost
of the part is increased.
The third option is to develop a resin which is
inherently high gloss, and achieving the desired
appearance right out of the mold. To develop an
inherently high gloss resin, it is important to develop
a smooth surface to increase the reflection from the
surface, figure 4. This option is used when tool
modifications or processing conditions do not permit
achieving the gloss level, or the application
requirements are not meet. New engineering resins
have been developed which improve the current level
of gloss in commercial applications.
MATERIAL
An experimental grade of polyester blend with high
gloss was selected throughout the study. It is a 15%
glass-filled polyester blend (PBT/PET) featuring high
surface gloss and high flow for long flow channels.
The formulation of this grade is proprietary.
The challenges in a polyester blend for a gas assist
injection molding process are to develop a high gloss
material with no increase in cycle time, it is colorable
in different colors, maintains a good balance of
mechanical properties, high flow in order to fill 760
mm with one gate, and all at a reasonable raw
material cost.
In order to have a high gloss, the PET in the polyester
blend reaches the surface quicker than the PBT and it
provides the best surface appearance. The formulation
contains a color package for high gloss. A hot mold
temperature is necessary for high gloss and best
appearance, and for crystallizing the PET.
For polyester blend, an inherently high gloss resin can
be formulated to achieve gloss values of 90 to 100
right out of the mold in the conventional injection
molding. The new formulation is colorable and
maintains excellent indoor UV stability, scratch
resistance, stain resistance, mechanical strength for
bearing weight and creep resistance, and chemical
resistance to detergents, cleaners and chemicals.
EQUIPMENT AND PROCESS to measure gloss levels on the samples. A sample size
of five parts was taken for each color studied and the
The rod-shaped part was produced in a mold of two average of each was used for the results.
cavities with a combination of hot runner and cold
runner systems. Figure 5 shows the molded part, the EXPERIMENTAL RESULTS
front “show side” is smooth. The back side has
“bumps” or grip features. The front side must look Due to the shape of the grips on the backside of the
glossy for best appearance. Figure 6 shows the cross part, it was a difficult to measure that area, so only
sections of the part. The cavities are highly polished the gloss level of the front “show side” is reported.
(SPI-A2 as minimum) in stainless steel, preferably for The gloss level was 86.7% on the “show side” of the
best appearance. The part is 760 mm long, and the part. The gloss value was very close to the
cavity is filled with one gate and one gas pin. Gas conventional injection molding parts with a gloss
assisted injection molding experiments were level from 90 to 100%. The parts injected with
conducted with a 350 ton clamping force. The current commercial grades have a gloss level of 55%.
injection molding machine was utilized in The gas assisted parts replicated the surface of the
conjunction with a gas injection control unit where mold.
the gas and polymer entered the mold at separate
locations. The mold cavities were cleaned and CONCLUSIONS
polished very well before starting up.
On rod-shaped parts, the gloss level was very close to
The processing conditions for the polyester blend the conventional injection molding parts when a high
followed the recommended material guidelines, but gloss polyester blend is used, and it is better than
during the material trials, some parameters were current commercial grades injected into the same
adjusted for the new polyester blend. The drying mold at the same processing conditions.
temperature was increased from 121 to 135°C in
REFERENCES
order to have a moisture level below 0.01%, required
for the PET in the polyester blend. A high surface
[1]Paul Dier, Richard Goralsky, Gass Assist Injection
mold temperature of 128°C was required for best
Molding, Bauer, 2000, USA.
appearance and to crystallize the material. The
A side, or stationary side of the mold, was hotter
[2]Hansen, Michael, “Application Examples for Gas-
because it is the show side of the part versus the
Assisted Injection Molded Parts”, Journal of Injection
moving side. The material required high melt
Molding Technology, V0l.3, No.3, September 1999.
temperature of 270°C for covering the fiberglass on
the surfaces of the parts. The temperatures of the hot
[3]http://machinedesign.com/article/gas-assist-
runner system were setup slightly lower than the melt
molding-not-just-for-hollow-parts-0809 (2010).
temperature. In the case of temperatures, the goal was
to find a balance between appearance, cycle time, and
[4]http://kiindustries.thomasnet.com/item/all-
avoiding ejector pin push on the part because the
categories/injection-molding/item-1003?&forward=1
material was too soft coming out of the mold, figure
7. At times, the gas pin got dirty and clogged with
[5]Cooper, C., Experimental Studies in Gas-Assist
material and the gas could not vent out of the part and
Injection Molding to Investigate Residual Wall
the parts ruptured or “popped” when the mold
Thickness and Gloss Levels, SPE Technical paper,
opened. This gas assist process was also optimized in
2005.
order to produce the highest quality part, by
minimizing the cycle time and avoiding pin push. The
gas pressure was 85bar and the hold pressure in
conventional injection molding was 950bar.

Shot to shot consistency was maintained as accurately

as possible for achieving the desired weight of the
part. Parts were weighed to verify consistency.

The material colors for this analysis were bisque,

black and white. A “60 degree” gloss meter was used
NOTICE TO USERS: To the best of our knowledge,
the information contained in this publication is
accurate; however, we do not assume any liability
whatsoever for the accuracy and completeness of
such information. Any values shown are based on
testing of laboratory test specimens and represent data
that fall within the standard range of properties for
natural material. Colorants or other additives may
cause significant variations in data values. Any
determination of the suitability of this material for
any use contemplated by the users and the manner of
such use is the sole responsibility of the users, who
must assure themselves that the material subsequently
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or use, and part design for any use contemplated by
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