Global W-IMMS

Global W-IMMS

Manufacturing Sixth Edition

Standards Issued: 1-Nov-2022
FORD GLOBAL MANUFACTURING STANDARD
CONTROL OF PLASTIC INJECTION MOLDING PROCESSES
W-IMMS
Sixth Edition
Copyright © 2022 Ford Motor Company. All rights reserved.

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ACKNOWLEDGEMENT
Plastic Injection Molding Technical Club

Supplier Technical Assistance
Global Core PD Body Interior Tooling
Global Core PD Body Interior CAE
Global Core PD Body Exterior CAE
Global PTI Analytical Product Engineering
Core Materials Engineering and Testing
Design Quality
Global Chassis Controls

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REVISION NOTES
Date Version Major Changes

nd
January 10, 2013 2 edition In Sections 1 through 5, revised and added sentences when needed.
e.g. use of “shall” instead of “should” to emphasize a mandatory
requirement, addition of the purpose of “Critical Response List”
January 10, 2013 2nd edition In Section 6, added two special applications: 6.9 Mucell® Process
and 6.10 Natural Fiber Reinforced Polypropylene
January 30, 2013 2nd edition In Appendix C, added fill time as process monitoring item
June 10, 2015 3rd edition In Section 3, added 3.2 Machine Robustness
rd
June 25, 2015 3 edition In Appendix A, added A1.2 Machine Robustness
November 5, 2015 3rd edition In Section 2, added 2.2 Appearance Approval Standard
November 5, 2015 3rd edition In Section 4, added 4.5.2 Monitoring of Part Appearance
November 5, 2015 3rd edition Added Appendix D, Evaluation Tools for Comparing to Minimum
Appearance Standard
November 11, 2015 3rd edition Added Appendix E, W-IMMS Compliance Checklist
December 15, 2017 4th edition Developed Appendix A “Plastic Injection Molding Manufacturing
Feasibility Assessment: Part, Mold, and Molding Process”
December 15, 2017 4th edition Added subsection 3.1 “Plastic Injection Molding Manufacturing
Feasibility Assessment” and a new requirement to use Appendix A to
assess manufacturing feasibility during each stage of injection-
molded product development.
December 15, 2017 4th edition Consolidated the contents of Appendix A and Appendix B in W-
IMMS (3rd edition) into Appendix B “Selected Procedures and
Methods for Evaluating Machine and Mold Robustness and
Developing Molding Process”.
June 7, 2018 4th edition Expended contents in subsection 4.7 “Use of Materials Identification
Labels” in W-IMMS (3rd edition) and change the title to 4.7 “Material
Labeling and Verification”.
February 15, 2021 5th edition Split Appendix A into two portions, A1 “Plastic Injection Molding
Preliminary Manufacturing Risk Assessment” and A2 “Mold and
Molding Process Robustness Verification”.
February 15, 2021 5th edition Revised part 1 “Part Design for Plastic Injection Molding” of
Appendix A1 by adding assessment items on material, texture and
part requirement and historical concerns.

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February 15, 2021 5th edition Modified subsection 3.1 “Plastic Injection Molding Manufacturing
Risk Assessment” to make conducting “preliminary manufacturing
risk assessment” and conducting “mold and molding process
robustness verification” separate requirements.
October 9, 2022 6th edition Added subsection 4.3.2 Restart and In-process Material Change
Procedure.
October 9, 2022 6th edition Changed Section 4.7 from “Material Labeling and Verification” to
“Labeling, Verification, and Traceability”. Added subsections 4.7.1
and 4.7.2 to set separate requirements for “material labeling and
verification within molding system” and “traceability of molded parts
in the product delivered to Ford plant”.
October 9, 2022 6th edition Added Section 5.5 “Smart Mold and Machine Monitoring
Technologies for Industry 4.0”
October 9, 2022 6th edition Revised Appendix A1 and Appendix E to improve clarity of the
requirements. There are three main additions to Appendix A1: (1)
Cross reference to MFSOW (a mold flow checklist developed by PD
interior tooling group); (2) Guideline to check whether knit line is
located on high stress sections; (3) Guideline to adopt 3D printed
conformal cooling inserts for hot spots identified during cooling
analysis.

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TABLE OF CONTENTS
1. SCOPE …………………………………………………………………………………………... 7
1.1 GENERAL DESCRIPTION ………………………………………………………………… 7
1.2 APPLICATIONS AND LIMITATIONS ………………………………………………....…. 8
2. GENERAL REQUIREMENTS …………………………………………………………………. 9

2.1 ENGINEERING AND PROCESS SPECIFICATIONS …………………………………...... 9
2.2 APPEARANCE APPROVAL STANDARD ……………………………………………....... 9
2.3 CONTROL PLAN …………………………………………………………………………… 9
3. PART, MOLD, MACHINE, AND PROCESS ROBUSTNESS EXPECTATIONS ……………. 10

3.1 PLASTIC INJECTION MOLDING MANUFACTURING FREASIBILITY
ASSESSMENT…………………………………………………………………………………....... 10
3.2 PART AND MOLD DESIGN FOR MANUFACTURING …………………………….…… 10
3.3 INJECTION MOLDING PROCESS DEVELOPMENT ………………………….………... 11
3.4 MACHINE ROBUSTNESS ……………………………………………………….………... 14
4. PROCESS CONTROL AND MONITORING EXPECTATIONS ………………………….….. 15

4.1 PROCESS SPECIFICATION …………………………………………………….………..... 15
4.2 DRYING ………………………………………………………………………….…….….... 15
4.3 PROCESS STARTUP, RESTART, AND IN-PROCESS MATERIAL CHANGE ………… 16
4.4 IN-PROCESS MONITORING ………………………………………………........................ 17
4.5 FIRST AND LAST PIECE INSPECTION ……………………………………….……….... 18
4.6 PROCESS CHANGES …………………………………………………………………….... 19
4.7 MATERIAL LABELING, VERIFICATION AND TRACEABILITY …………………… 19
5. MOLD AND MACHINE PREVENTIVE MAINTENANCE EXPECTATIONS …………..….. 21

5.1 SHORT AND LONG TERM MOLD PREVENTIVE MAINTENANCE …………….…..... 21
5.2 MOLD SPECIFIC PREVENTIVE MAINTENANCE ……………………………….….….. 21
5.3 DETECTION OF EMERGING MOLD MAINTENANCE NEEDS ………………….…..... 21
5.4 MACHINE PREVENTIVE MAINTENANCE .………………………………..……..….… 22
5.5 SMART MOLD AND MACHINE MONITORING TECHNOLOGIES 22
5.6 SPARE PART ………………………………………………………………………….….… 23
6. ADDITIONAL GUIDELINES FOR SPECIAL APPLICATIONS …………………………...… 24

6.1 MOLDING FOR CHROME PLATING …………………………………………………...... 24

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6.2 SENSOR OVERMOLDING …………………………………………………………..….…. 25

6.3 HIGH FILLER CONTENT MATERIALS ……………………………………………….…. 27
6.4 THERMOSET PLASTICS ………………………………………………………………...... 28
6.5 COLOR AT PRESS …………………………………………………………………………. 29
6.6 LONG GLASS FIBER REINFORCED POLYPROPYLENE ………………………….…… 30
6.7 STORING AND SHIPPING MOLDED NYLON PARTS ……………………………….…. 30
6.8 LIVING HINGE……………………………………………………………………………… 31
6.9 MUCELL® PROCESS ……………………………………………………………….……… 31
6.10 NATURAL FIBER REINFORCED POLYPROPYLENE ………………………………… 34
7. CRITICAL RESPONSE LIST …………………………………………………………………... 35
APPENDICES
A1: PLASTIC INJECTION MOLDING PRELIMINARY MANUFACTURING RISK

ASSESSMENT ………………………………………………………………...…………………… a 1.1
A2: MOLD AND MOLDING PROCESS ROBUSTNESS VERIFICATION ……………………. a 2.1
B: RECOMMENDED PROCEDURES AND METHODS FOR EVALUATING MACHINE

AND MOLD ROBUSTNESS AND DEVELOPING INJECTION MOLDING PROCESS ……… b1
C: RECOMMENDED METHODS AND FREQUENCIES FOR IN-PROCESS MONITORING

.............................................................................................................................................................
c1
D: EVALUATION TOOLS FOR COMPARING TO MINIMUM APPEARANCE STANDARD

.............................................................................................................................................................
d1
E: W-IMMS COMPLIANCE CHECKLIST ..................................................................................... e1

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1. SCOPE
1.1 GENERAL DESCRIPTION
This standard defines the requirements for the control of plastic injection molding processes. These
requirements reflect the following manufacturing concepts:
• Robust part and mold designs lay the foundation of a robust injection molding process.
• Process consistency, shot to shot and run to run, is the first step towards producing quality injection
molded parts.
• Startup verification plays an important role in preventing injection molding process mean shift over
time.
• In-process machine and process status monitoring is necessary to provide an early warning for
potential quality deviations.
• Effective machine and mold preventive maintenance contributes to process consistency in long-term
production.
• Proper verifications are necessary when changes in process, part, mold, or machine take place.
There are five appendices in W-IMMS. These appendices provide guidelines, or methods or procedures for
injection molding manufacturing feasibility assessment, molding process development, molding process
monitoring, appearance inspection, as well as W-IMMS compliance.
Appendix A “Plastic Injection Molding Manufacturing Feasibility Assessment: Part, Mold, and Molding
Process” provides a tool for assessing the robustness of part design, mold design, mold construction, and
molding process at each stage of the development of an injection molded part.
• Part design
• Initial mold flow simulation without mold cooling channels
• Mold flow simulation with mold cooling channels
• Mold design
• Mold tryout
• Mold home line tryout
Appendix B “Selected Procedures and Methods for Machine and Mold Robustness Check and Molding
Process Development” lists recommended procedures and methods that are used in the development of
molding process, verification of machine and mold robustness, and establishment of production startup
window.
Appendices C “Recommended Methods and Frequencies for In-Process Monitoring” and D “Evaluation Tools
for Comparing Production Parts to Minimum Appearance Standard AAR” list recommended methods and
frequencies for in-process monitoring and evaluation tools for appearance quality respectively.

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Appendix E: “W-IMMS Compliance Checklist” provides a tool for the molder to assess whether its injection
molding system meets the requirements in W-IMMS. The molder should always refer to the main text of this
standard for details and clarification of each requirement. To facilitate the assessment, an Excel workbook of
the checklist (also known as CQI-23 Ford Specific Assessment) is available to Ford suppliers via Ford
Supplier Portal.
When a plastic part quality issue arises, Section 7 “Critical Response List” provides a list of recommended
actions for suppliers during problem solving.
1.2 APPLICATIONS AND LIMITATIONS
This standard applies to all plastic injection molded production and service parts manufactured by tier one and
sub-tier suppliers to Ford Motor Company. Exceptions to the standard shall be reviewed and concurred by
Ford STA (Supplier Technical Assistance).
The intent of this standard is to deploy specific plastic molding best practices and lessons learned in part
design, mold design, mold tryout, and molding process development, as well as in the prevention of recurrence
of quality issues. For plastic molding general quality practices, molding suppliers that are new to Ford Motor
Company are required to conduct self-assessment by using AIAG CQI-23: Special Process: Molding System
Assessment.
This standard uses key elements in injection molded part design, mold design, and mold construction as design
for manufacturing indicators, defines assessment methods, and sets part and mold robustness criteria based on
benchmark data. However, the user of this standard should not construe the standard as a part design standard
or a tooling standard for injection-molded parts. Whenever a conflict between this standard and an applicable
engineering specification or between this standard and an applicable tooling specification arises, The Team,
consisting of Ford Engineering, Ford STA, and the supplier or the suppliers, shall make the final decision.
In this standard, the word “SHALL” is used to indicate a requirement. The molder needs to take immediate
actions to address any area that is not in compliance with the requirement. The word “SHOULD” is used to
indicate a recommended best practice only.

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2. GENERAL REQUIREMENTS
2.1 ENGINEERING AND PROCESS SPECIFICATIONS
The supplier shall have an engineering drawing or specification that lists engineering requirements of the part.
Engineering requirements include the material specification (if applicable, material type and grade),
dimensions, and performance requirements.
The supplier shall have a mold design that includes specifications for mold components, locking mechanism,
ejection mechanism, and cooling lines.
The supplier shall establish a process specification that defines operating ranges of machine variables such as
barrel temperature, transfer position, and screw velocity etc.
2.2 APPEARANCE APPROVAL STANDARD
The supplier shall comply with Ford G-DCAP (Global Decorative Component Approval Process). The
document is available to Ford suppliers via Ford Supplier Portal.
Part appearance is a product characteristic designated in the DFMEA with the “YS” symbol (potential
significant characteristic). All production parts shall meet appearance requirements for color, texture,
gloss, parting lines and other surface defects. The minimum appearance standard is defined by the
stickered part signed off by Ford Design Quality along with a corresponding AAR (Appearance Approval
Report). For color, production parts shall be in the correct color space trending direction as defined by
Ford Design Quality. The supplier shall refer to Appendix D for appearance evaluation method and tools.
The supplier shall retain the stickered part for the life of a vehicle program. All stickered parts shall be stored
in a dedicated and clearly defined location.
2.3 CONTROL PLAN
A written Control Plan is required for the processing of all injection-molded parts covered by this standard.
The Control Plan shall be linked to Process Failure Mode and Effect Analysis and shall contain proper reaction
plans to handle process deviations. The Control Plan should include first and last piece inspection. For process
monitoring purpose, parameters that reflect feedbacks from the molding process should be used.

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3. PART, MOLD, MACHINE AND PROCESS ROBUSTNESS EXPECTATIONS
3.1 PLASTIC INJECTION MOLDING MANUFACTURING RISK ASSESSMENT
The supplier shall use Appendix A1 “Plastic Injection Molding Preliminary Manufacturing Risk Assessment”
or an alternative assessment tool to assess manufacturability of injection-molded plastic parts based on part
design rules, quality history of surrogates, and mold flow simulations during design stage. If one or more high-
risk items are identified during the assessment, the team involved shall investigate, plan and implement risk
mitigation actions before the mold is constructed. For example, when a gas trap location on a class A surface is
identified by analysis, the molder could consider wall stock adjustment or tool solutions such as flow channel
and vent insert to move the gas trap out of the class A surface.
The supplier shall use Appendix A2 “Mold and Molding Process Robustness Verification” or an alternative
assessment tool to assess the robustness of production mold and molding process. If one or more high-risk
items are identified during the assessment, the team involved shall investigate, plan and implement corrective
actions. If corrective actions are not viable due to design or launch timing limitations, the supplier should
contain the risk by increasing process monitoring frequency and sampling size in production to protect the
quality of the parts delivered to Ford plants.
If the supplier elects to use alternative assessment tools, the supplier shall submit them to Ford STA and for
review and concurrence in advance.
3.2 PART AND MOLD DESIGN FOR MANUFACTURING
The supplier shall use a systematic approach to part design, mold design, mold construction, and mold tryout.
The development process should include, but not be limited to, the following steps:
• Material selection
• Basic part design
• Structure analysis if applicable
• Part design review
• Mold flow analysis
• Mold design
• Mold design review
• Mold construction follow-ups
• Mold and molding process tryouts
If responsible for part design, the supplier shall verify material selection by using material data or benchmark
to ensure that the material has the necessary material compatibility, chemical and environmental (temperature,
humidity, weathering etc.) resistance, toughness and other physical and mechanical properties to meet design
intent unless otherwise specified by Ford engineering.
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The supplier shall apply plastic part design principles and follow an applicable part design standard or
guidelines that are specified, recommended, or concurred by Ford Motor Company. At the minimum, the
standard shall include design details such as base wall thickness, radius, and draft angle etc.
The supplier shall apply mold design knowledge to its design and follow applicable mold design guidelines
(internal or external) that are recommended or concurred by Ford Motor Company.
The supplier shall conduct a benchmark study or run a preliminary mold flow simulation to determine initial
size, shape and location of sprue, runner and gate for the mold. The molder shall use the knowledge obtained
as inputs and conduct mold flow simulations to predict melt flow pattern, locations of knitline and gas trap.
Furthermore, when applicable, the molder shall avoid locating knitline on critical loading path or knitline and
gas trap on surfaces that require high appearance quality. Potential options could include modifying part and
mold designs such as wall thickness and gate locations, as well as using flow leader or flow restrictor or both.
The supplier shall conduct mold-cooling analysis aimed at minimizing temperature variations in the part
during cooling. If excessive temperature variation is predicted, such as presence of a “hot spot”, the molder
should consider modifying the part design (e.g. wall thickness increase or decrease in affected area) to
minimize the temperature variation. If part design change is not feasible, the molder should consider adopting
or modifying localized cooling options for the mold to minimize the variation. Examples of localized cooling
options include traditional local cooling components such as baffles and high conductivity inserts or novel
cooling techniques such as CO2 spot cooling and conformal cooling inserts.
The supplier shall take into consideration of the quality history of the commodities in the part and mold
designs. For parts that are prone to warpage, in conjunction with cooling analysis, the molder shall perform
warpage analysis. If unacceptable level of warpage is predicted, the molder shall investigate main factor or
factors that cause the warpage and explore options in the designs of part and mold, as well as processing to
minimize warpage.
3.3 INJECTION MOLDING PROCESS DEVELOPMENT
3.3.1 KEY PROCESS VARIABLES
During process development, the molder shall use a systematic approach to establish following process key
input variables and record key process output variables:
Key process input variables
• Drying temperature (if applicable)
• Material dwell time in the dryer (If applicable)
• Barrel temperature
• Hot drop/manifold temperature (if applicable)
• Screw RPM
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• Back pressure
• Nozzle temperature
• Gate opening and closing sequence (if applicable)
• Screw velocity or velocity profile during fill
• V-P switchover position
• Pack time (if applicable)
• Screw velocity during pack (if applicable)
• Pack pressure (if applicable)
• Hold time
• Hold pressure (set point, upper and lower limits)
• Cooling water (or other medium) temperature
• Cooling water (or other medium) flow rate
• Cooling time
Key process output variables
• Moisture content (if applicable)
• Melt temperature
• Fill time
• Peak pressure (for hydraulic machines)
• Cushion size
• Cycle time
• Peak cavity pressure, or cavity pressure curve, or part weight
3.3.2 MELT TEMPERATURE AND RESIDENCE TIME VERIFICATION
During process development, the molder shall verify that melt temperature is within the range recommended
by the resin supplier. The molder shall also verify that the melt residence time does not exceed the maximum
residence time established by material supplier. The Team, consisting of Ford Engineering, Ford STA, the
material supplier, and the molder, shall review the deviations. Refer to Appendix B “B1.1 Residence Time
Estimate” for a recommended method for residence time estimate.
3.3.3 ESTABLISHING KEY PROCESS INPUT VARIABLES
The molder should establish process input variables by using Scientific Molding approach. Shown below is an
example of the development process:
(1) Set barrel temperature, nozzle temperature (hot manifold temperature), screw RPM, and back pressure such
that the melt temperature is in the mid-range of resin manufacturer recommended limits.
(2) Set V-P switchover position.
a. If two-stage decoupled molding technique is adopted, set V-P (fill stage to pack/hold stage) switchover
position at approximately 95% to 98% cavity full.
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b. If three-stage molding technique is adopted, set the V-P (fill stage to pack stage) switchover position at
approximately 85% to 95% cavity full and set the pack to hold switchover at a target cavity pressure.
(3) Set screw velocity during fill such that the material viscosity does not change drastically with changes in
fill rate. Refer to Appendix B “B2.1 Viscosity Curve and Velocity Linearity Determination” for a
recommended method.
(4) Verify that the highest pressure during fill is 85% or less than the pressure limit set for this stage. If the
pressure is more than 85% of the pressure limit, adjust pressure limit, or fill rate (screw velocity), or both and
repeat the verification. Deviations from the 85% rule should be reviewed by a team consisting of Ford
Engineering, Ford STA, and the supplier or suppliers.
(5) Set hold time per gate seal time when applicable. Refer to Appendix B “B2.2 Gate Seal Time
Determination” for a recommended method.
(6) Set pack and hold pressure.
a. If the two-stage decoupled molding technique is adopted, set the hold pressure such that cavity pressure
or part weight is in the mid-range of the process window.
b. If the three-stage decoupled molding is adopted, set both pack and hold pressures such that cavity
pressure or part weight is in the mid-range of the process window.
(7) Optimize the cooling time and tool temperature by using design of experiment. Refer to Appendix B “B2.3
Cooling Time Estimate” for a recommended method.
3.3.4 ESTABLISHING PROCESS WINDOW, STARTUP WINDOW, AND STARTUP PROCEDURE
During process development, the molder shall establish a process window in term of cavity pressure profile or
peak cavity pressure, or part weight (if cavity pressure is not available), or an equivalent process indicator. An
equivalent process indicator is used only if cavity pressure is unavailable and variation of material specific
gravity within the same material lot exceeds 1.5%. For example, a part is injection-molded from 60% glass
filled nylon in a mold that does not have cavity pressure sensing capability. Due to high glass content,
variation of material specific gravity within the same material lot exceeds 1.5% and thus part weight does not
correlate with cavity pressure (thus dimension) well. Therefore, the “torque-to-fail” value of a selected screw
boss on the part or a representative dimension could be chosen as a process indicator instead of part weight.
Within the process window, parts from all cavities shall meet functional, dimensional, and appearance
requirements. In addition, there shall be no processing issues such as part ejection difficulty. Refer to Appendix
B “B2.4 Process Window Determination” for a recommended method for establishing a process window in
terms of cavity pressure or part weight.
Once the process window is determined, the molder shall determine an initial production startup window
around the middle of the process window developed. The molder should verify the validity of the initial startup
window in subsequent production runs. The purpose of the startup window is to "center" the process at the
startup, restart, or in-process material lot change and thus limit process shift due to changes such as variations
in material property and ambient conditions etc. that are typically not controlled in molding process. Refer to
Appendix B “B3 A Method for Establishing Production Startup Window” for a recommended method of
establishing initial startup window and verifying startup window subsequently.
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During process development, the molder shall also determine or confirm proper procedure for production
startup, restart, and material change, including, but not being limited to,
• Heat soak time for machine and mold (barrel, hot manifold if applicable and mold halves)
• Purging
• Number of initial full shots scraped before “first piece” (if applicable)
3.4 MACHINE ROBUSTNESS
When selecting molding machines for all new Ford parts, the molder shall verify that molding machines meet
the requirements that are essential to its capability of providing consistent shots:
• Control and monitor pressure in the hydraulic cylinder (for hydraulic machines). Pressure transducer
has a resolution of 50 psi at the minimum in the operating range.
• Control and monitor screw velocity. The deviation of actual velocity from the set velocity is 20% or
less in the operating range.
• Control and monitor stroke. Position transducer has a resolution of 0.2% of the full stroke at the
minimum.
• Control and monitor time. The timers have a resolution of 0.05 seconds at the minimum.
• Monitor fill time, peak pressure, cushion size and cycle time during production.
The molder shall ensure that the check ring functions properly by conducting “Dynamic Check Ring
Repeatability Test” or an equivalent evaluation method on new and existing machines used to mold Ford parts
and verifying that the check ring leakage is 3% or less. Refer to Appendix B “B1.3 Check Ring Repeatability
Determination” for a recommended method.
Check ring leakage verification frequency for existing molding machines shall be as follows:
• After a check ring assembly repair or replacement event
• As a long-term preventive maintenance item at a frequency determined by the molder (but no less than
once every two years)
For hygroscopic materials such Nylon and Polycarbonate, the molder shall use a regenerative desiccant type
dryer. The molder shall select a dryer that has sufficient capacity so that material dwell time meets material
vendor recommendation.
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4. PROCESS CONTROL AND MONITORING EXPECTATIONS
4.1 PROCESS SPECIFICATION (SETUP SHEET)
The molder shall have a documented process specification for key process input variables. Refer to subsection
3.3.1 “Key Process Input Variables” for a list of variables. In particular, the molder should specify a set point
and an operating window (or a limit) for following variables:
• Drying temperature (if applicable)
• Hot drop/manifold temperature (if applicable)
• Back pressure
• Pack pressure (if applicable)
• Hold pressure
• Cooling water (or other medium) temperature
• Cooling water (or other medium) flow rate
4.2 DRYING
If the plastic material is hygroscopic, the molder shall dry the material before molding. For non-hygroscopic
material, drying is recommended as a best practice, especially in facilities where humidity on the
manufacturing floor is high.
The molder shall use a regenerative desiccant dryer to ensure consistent drying when molding hygroscopic
materials such as PC and Nylon. Exception is possible only under two conditions. First, the part is not used for
an application that is critical to safety. Second, there is data that proves non-conforming dryer effectively dries
the plastic material over multiple lots and under all ambient conditions. The data should include, at a
minimum, moisture content results collected from a period 12 months or longer.
During process development, the molder shall verify the capacity of the drying unit to ensure that the material
dwell time in the drying unit is within the specified process window for the drying time. The molder shall also
determine the minimum material level in the dryer to ensure sufficient dwell time in a continuous molding
operation.
When molding hygroscopic materials such as PC and Nylon, the molder shall verify the moisture content at
the start of a production run. During the course of a production run, the molder should monitor the moisture
content at a minimum frequency of once per day. To ensure sufficient dwell time for the plastic material in the
dryer, supplier shall control the minimum material level in the dryer. If a below-minimum-level condition has
occurred, the molder shall follow proper reaction plan defined in Control Plan to address the non-
conformance.
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4.3 PROCESS STARTUP
4.3.1 STARTUP AND SHUTDOWN PROCEDURE
The molder shall standardize startup procedure. The procedure includes, but is not limited to,
• Heat soak (barrel, hot manifold if applicable, and mold halves)
• Opening slide gate on the hopper
• Screw RPM during initial charging
• Purging of hot manifold (if applicable) and barrel
In startup procedure, the molder shall also cover mold-specific items such as
• Number of discarded initial shots (after short shot, but before “first piece” production part)
• Removing rust preventive from mold with highly-polished surface
Similarly, the molder shall standardize the Machine Shut Down procedure.
4.3.2 RESTART AND IN-PROCESS MATERIAL CHANGE PROCEDURE
The molder shall standardize procedure for restart after unplanned machine downtime. The procedure shall
ensure that melt in the barrel and hot manifold during downtime is exhausted before making production parts.
The procedure includes, but is not limited to,
• Purging of hot manifold (if applicable) and barrel
• Number of discarded initial shots (after short shot, but before “first piece” production part)
Similarly, the molder shall standardize procedure for in-process change of material lot and colorant. For
material lot change, in the case of hygroscopic materials, the procedure shall ensure that in-process material lot
change does not lead to shortened drying time. For colorant change, the procedure shall ensure that production
parts after colorant change meet color and appearance acceptance criterion.
4.3.3 STARTUP VERIFICATION
At production startup, restart, and in-process material lot change, the molder shall verify the following items:
• Temperature and flow rate of cooling water (or other cooling medium) when applicable – For startup
• Material type and grade – For startup and in-process material lot change
• Moisture content (when applicable) – For startup, restart (if applicable), and in-process material lot
change
• Key process input variable settings (refer to subsection 3.3.1) – For startup
• No gate blockage (applicable for molds with two or more valve gates) – For startup and restart
• Cavity and vent cleaning – For startup
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• Barrel purging – For startup and restart
At production startup, restart, and in-process material lot change, the molder shall verify that the molding
process (in terms of cavity pressure profile, or peak cavity pressure, or part weight, or an equivalent indicator)
is within the established startup window. Refer to subsection 3.3.4 “Establishing Process Window and Startup
Window” for details regarding startup window. For large molds, the molder should repeat this verification
after cavity temperature has stabilized (e.g. 30 minutes after production has started).
If the process is not within the startup window, the molder should make adjustments to pack or hold pressure
and bring the process back into the startup window. If pack or hold pressure has exceeded the limit in the
process specification because of the adjustments, the molder should investigate the root cause before starting
production.
4.4 IN-PROCESS MONITORING
4.4.1 MONITORING OF PROCESS CONDITIONS
A molder shall monitor process condition during the course of a production run. Listed below are key process
output variables that are indicator of process condition:
• Moisture content (when applicable)
• Fill time
• Peak hydraulic pressure (for hydraulic machines)
• Cushion size (also covered in 5.4 Machine Preventive Maintenance)
• Cycle time or screw recovery time (also covered in 5.4 Machine Preventive Maintenance)
• Cavity pressure (part weight if cavity pressure monitoring is not available, or an equivalent indicator if
cavity pressure monitoring is not available and part weight monitoring is not feasible)
The molder should also monitor following items:
• Hot drop or hot manifold temperature (when applicable)
The molder should refer to Appendix C "Recommended Methods and Frequencies for In-Process Monitoring"
for methods and frequencies recommended in in-process monitoring.
4.4.2 MONITORING OF PART APPEARANCE
Production Part Appearance

Production parts shall meet minimum appearance standard for color, gloss, texture, parting lines and other
surface defects. During a production run, color, gloss, and texture of the parts shall be between the Design
Intent master and the appearance of the signed-off AAR (stickered) part. For color, production parts shall
be in the correct color space trending direction as defined by Ford Design Quality.
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Refer to Appendix D “Evaluation Tools for Comparing to Minimum Appearance Standard”.
Sample Size and Frequency

Ford Design Quality recommends the following minimum sample size and frequency for in process monitoring
of part appearance:
• One part for each inspection
• Both before and after each color change, material change, or process condition change
• Every eight (8) hours for longer production run without any changes
4.5 FIRST AND LAST PIECE INSPECTION
4.5.1 FIRST AND LAST PIECE INSPECTION WORK INSTRUCTION
The molder shall use a systematic approach to identify and document potential molding defects that could lead
to functional failure in assembly or sub-assembly. Shown below are examples of recommended actions to
identify and document potential molding defects that could lead to functional failure in assembly or sub-
assembly:
• Identify potential molding defects and their locations from mold flow analysis, molding trials, and
benchmarking.
• Identify the potential molding defects that would lead to functional failure in the assembly or sub-
assembly by analyzing interactions between the molded part and surrounding parts when assembled.
Examples of potential molding defects that would lead to functional failure include weak weld-line,
flash, missing rib, and warpage.
• Document locations of these molding defects with the aid of a sketch or a picture and label each
location with an alphabet or a number. The molder should also specify inspection sequence based on
established priority.
The molder shall also identify part features formed by weak mold components (such as a small core pin) that
are susceptible to damage without detection in production. The molder shall document these potential missing
features in the inspection instruction.
In First and Last Piece Inspection Work Instruction, the molder shall prioritize the inspection of potential
molding defects and potentially missing features that could lead to functional failure in assembly or sub-
assembly.
4.5.2 INSPECTION
The molder shall conduct first and last piece inspection based on the inspection instruction established.
In the first piece inspection, the molder should verify
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• Absence of molding defects that would lead to functional failure in the assembly
• Part appearance that is equal to or better than minimum appearance standard for color, texture, gloss,
parting lines and other surface defects (evaluated by Quality Assurance personnel)
• Presence of features
• Product characteristics that are designated CC, SC, or HIC (typically, dimensions)
In the last piece inspection, the molder should verify

• Absence of molding defects that would lead to functional failure in the assembly
• Part appearance that is equal to or better than minimum appearance standard for color, texture, gloss,
parting lines and other surface defects (evaluated by Quality Assurance personnel)
• Presence of features
4.6 PROCESS CHANGES
When changing one or more key process input variables, or material lot in the middle of a production run, the
molder shall follow first piece inspection instruction (Section 4.5) to confirm part quality. The molder shall
also confirm that the molding process is still within the startup window.
When a Supplier Request for Engineering Approval requires PV testing on parts molded with regrind, the
molder shall use maximum specified regrind amount in the molding process to produce sample. For example,
if 20% regrind is the maximum amount of regrind specified, the molder shall mold the PV samples with 20%
regrind.
When a Supplier Request for Engineering Approval involves change of supplier or manufacturing site, the
molder shall verify the plastic material used at the new supplier or at the new manufacturing site against the
signed-off Bill of Material.
Before putting a capacity mold or a refurbished mold into production, the molder shall complete dimensional
layout and an assembly trial run before delivery of production parts to Ford Assembly Plants.
4.7 LABELING, VERIFICATION, AND TRACEABILITY
4.7.1 Material Labeling and Verification Within Molding System
The molder shall use material identification labels throughout the molding system that includes on-site
material storage, in-process material storage (if applicable), drying system (if applicable), and molding
machine. Examples include:
• Containers for in in-process material storage that feeds the hopper during a production run
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• Containers for holding material that is left in the hopper at the end of a production run
• Containers for transporting material that is left in the hopper or in-process storage at the end of a
production run
During receiving inspection, the molder shall verify the materials received and label them per its material
handling system requirement.
When handling materials, whether it is before production, in production, or after production, the molder shall
verify the material by matching material label with that on the work order or on the destination material
storage or both. The verification can be carried out either manually or by using a barcode scanning system.
The molder shall quarantine resins and colorants without proper raw material identification labels.
4.7.1 Traceability of Injection-molded Parts
Injection molds shall provide cavity identification (for molds with two or more cavities) and molding date
traceability markings (if feasible). A molded part in the product delivered to Ford plant shall be traceable to
the week of molding (at the minimum), along with material lot and process conditions. If the product delivered
to Ford plant involves multi-tier suppliers, the traceability for injection-molded parts shall be established and
maintained through the supplier chain.
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5. MOLD AND MACHINE PREVENTIVE MAINTENANCE EXPECTATIONS
5.1 SHORT-TERM AND LONG-TERM MOLD PREVENTIVE MAINTENANCE
The molder shall have a preventive maintenance program for production molds. The preventive maintenance
program shall cover both short-term and long-term preventive maintenance needs. The molder shall establish
the list of preventive maintenance items and frequencies based on benchmarking, recommendations from tool
shop, and historical data of the same or similar type of molds.
Short term preventive maintenance items should include, but not be limited to, cleaning buildup from vented
gases, removing plastic residuals on parting line, core, and cavity, applying lubricant to moving components,
applying rust preventive to mold cavities, as well as special procedure used in cleaning highly polished cavity
surfaces when applicable.
Long-term mold preventive maintenance should include, but not be limited to, disassembling the mold,
evaluating, cleaning, and greasing the moving mold components such as slides and ejector pins, checking for
vent depth and width, descaling or flushing cooling water channels, checking for integrity of seals and gaskets,
and checking for signs of leakage for molds equipped with hot manifolds.
5.2 MOLD SPECIFIC PREVENTIVE MAINTENANCE
The molder shall identify all moving components and non-permanent features such as ejector and core pins, as
well as other locations that are susceptible to damage and wear on each new mold.
The molder should document these potential “maintenance trouble” locations with the aid of a sketch or a
picture (preferably number each location) before volume production starts.
The molder shall verify the integrity of these potential “maintenance trouble” locations before or after each
production run. In the case that it is not feasible to verify the integrity of a "maintenance trouble” location
directly without disassembling the mold, the molder could assess it indirectly based on the quality of
corresponding locations on the molded part.
5.3 DETECTION OF EMERGING MOLD MAINTENANCE NEEDS
The molder shall have a system in place to record process changes made during a production run to correct a
molding quality issue. The responsible process personnel should mark the parts from the last shot before
making process change and hold them until the responsible maintenance personnel has reviewed both mold
and parts. An example of process record is a note on the log sheet by processing personnel regarding an
adjustment made to fill speed to eliminate a burn mark during production.
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The system shall alert maintenance personnel the emerging molding quality issue at the end of the production
run. Examples of notification:
• Sending e-mail from the processing personnel
• Issuing a yellow tag on the mold with a part attached and affected area marked
• Holding an onsite meeting to address the issue.
The responsible maintenance personnel (and process personnel) shall review the marked parts before process
change, inspect the suspect location(s) on the mold, determine whether mold issue has led to the process
change, and plan corrective actions.
5.4 MACHINE PREVENTIVE MAINTENANCE
The molder shall have a preventive maintenance program for molding machines. The preventive maintenance
program shall cover both short term and long-term maintenance needs. The molder shall establish the list of
preventive maintenance items and frequencies based on recommendations from machine vendors and
historical data from the same type of machines.
The molder should monitor two process output variables that reflect machine conditions and use the data for
longer-term preventive maintenance purpose.
• Screw recovery time (or cycle time, also cover in 4.4.1 Monitoring of Process Conditions)
• Cushion size (also covered in 4.4.1 Monitoring of Process Conditions)
Refer to Appendix C “Recommended Methods and Frequencies for In-Process Monitoring” for recommended
frequencies.
The molder should also monitor other machine characteristics for preventive maintenance purpose. Examples
of these characteristics include hydraulic injection pressure curve, quality of hydraulic oil, and thermographic
characteristics of electrical control box.
The molder shall verify check ring repeatability after check ring repair or replacement to ensure that check ring
functions properly. Refer to Appendix B “B1.3 Check Ring Repeatability Determination” for a recommended
method. The molder shall also verify check ring repeatability as a long-term preventive maintenance item. The
frequency of such verification shall be no less than once every two years.
5.5 Smart Mold and Machine Monitoring Technologies for Industry 4.0
The molder should adopt smart monitoring technologies for its mold and machine. Smart technologies are used
for molding cycle monitoring, cavity pressure monitoring, and mold temperature monitoring. For example, a
relatively inexpensive device called CVe Monitor can be installed on the mold to provide data such as cycle
count, cycle time, and mold temperature. The data can be used to generate alerts for preventive maintenance,
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cycle time, as well as molding process efficiency. When equipped with a press module, the device is also
capable of sending data wirelessly from the mold to a database in real-time. Reports generated from the real-
time data can be accessed anywhere in the world at any time.
5.6 SPARE PART
The molder shall identify spare part needs for critical components on all production molds and molding
machines (as well as other equipment and measuring devices in an injection molding facility). At the
minimum, the molder shall have spare parts on site based on availability, lead-time and the impact to delivery
of products to Ford Motor Company.
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6. ADDITIONAL GUIDELINES FOR SPECIAL APPLICATIONS
For molding processes list in this section, the molder shall follow additional guidelines besides requirements
and best practices listed in Sections 1 to 5.
In the case there is a conflict between a requirement in Section 6 and a requirement in Sections 1 to 5, the
requirement in Section 6 supersedes the requirement in Sections 1 to 5.
6.1 MOLDING FOR CHROME PLATING
6.1.1 PART DESIGN FOR CHROME PLATING
In addition to general guidelines of designing wall thickness, radius and draft angle (refer to Appendix A1),
guidelines listed below are conducive to a successful plating-on-plastic application:
(1) Avoid sharp edges and corners. All edges shall be rounded off to a radius of 0.8 mm or larger. At corners,
the minimum inside and outside radii shall be 0.8 mm and 1.6 mm respectively.
(2) Avoid V-shape grooves and use U-shape grooves instead. Limit the depth to 50% of their width or less.
(3) Ensure adequate distance between slots or holes. The width of slots or diameter of holes shall be at a
minimum two times of the depth of slots or holes.
(4) Avoid blind holes. If a blind hole is used, avoid blind holes with a diameter smaller than 5.5 mm, limit its
depth to no more than 50% of its width, and provide drainage holes whenever possible.
(5) Limit the thickness and height of ribs. The thickness and height of ribs shall not exceed 40% and 150% of
the wall thickness respectively.
(6) Avoid flat surfaces. Unless it is in conflict with a unique appearance requirement, crown the flat surfaces
with a minimum curvature of 0.015 mm/mm.
(7) Avoid thin wall design. The minimum wall thickness shall be 1.6 mm.
6.1.2 MOLD DESIGN FOR CHROME PLATING
In addition to general guidelines of designing melt delivery system, vents, and cooling lines, guidelines listed
below are conducive to a successful plating-on-plastics application:
(1) Polish cavities to a minimum of SPI A-3 finish (surface roughness less than 0.1 microns) unless otherwise
specified by customer.
(2) Use larger gate and shorter gate land. Gate size should be approximately 1.5 times of that for a non-plating
application. Limit the gate land length to 0.8 mm or less.
(3) Use hot runner system and sequential valve gating for larger parts if possible.
6.1.3 MOLDING PROCESS FOR CHROME PLATING
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Molding conditions listed below are conducive to a successful plating-on-plastics application:

(1) Use moderate fill rate. Both too low and too high flow rates lead to unacceptable plating quality. The
molder shall determine suitable fill rate by experiments once other molding conditions are set.
(2) Use a higher melt temperature. For ABS, the recommended temperature is between 250 oC and 265 oC. For
PC/ABS, the recommended temperature is between 275 to 285 oC (a higher melt temperature may require a
longer cooling time).
(3) Avoid low mold temperature. The recommended mold temperature is between 65 oC to 80 oC.
6.1.4 EVALUATION OF MOLDED PARTS FOR CHROME PLATING
Glacial acetic acid dipping test is commonly used to assess molded-in stress and hence plating adhesion risks.
The test method is as follows:
At room temperature, dip a molded part in glacial acetic acid, and observe color change. The color change is
indicative of stress whitening and can be used to indicate presence of molded-in stress on or near the part
surface. The more drastic the color changes, the higher the molded-in stresses. For ABS material, color change
typically appears at approximately 30 seconds of dipping. For PC/ABS material, dipping time will be from one
to three minutes. The supplier should refer to relevant Ford engineering specifications for any updates of the
test method.
6.2 SENSOR OVERMOLDING
The following additional requirements are applicable for sensor overmolding.
6.2.1 EQUIPMENT AND MOLD REQUIREMENTS
(1) The suppliers shall demonstrate that the size of the molding machine is appropriate for the application and
submit the data for review by Ford engineering and Ford STA.
(2) The supplier shall design the mold with cavity pressure monitoring capability.
(3) The supplier shall confirm the mold and machine conditions below prior to molding process development:
• Coolant flow rate and inlet and outlet coolant temperature
• Check ring integrity
• Calibration of all sensors
• Pressure response evaluation
• Load sensitivity evaluation
(4) Inserts for overmolding shall be free of burrs, contaminants, or any other condition that may be detrimental
to the overmolding process.
6.2.2 MOLDING PROCESS DEVELOPMENT
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In addition to process development defined in subsection 3.3 “Injection Molding Process development”, the
supplier shall perform the following:
(1) Capture data demonstrating sensitivity of cavity pressure to transfer point. Select transfer point properly to
assure no spike in cavity pressure due to transfer point variation.
(2) Establish an injection speed profile that fills the cavities as fast as possible, does not shift inserted
components, ensures bonding of melt ribs, and ensures that fill stage is not pressure-limited.
(3) Establish the upper limit of peak injection pressure. At this limit, there shall be no molding defects or
internal component damage. Set alarm limit of peak injection pressure at least 5% lower than the upper limit.
(4) Determine the process window based on cavity pressure. Within the lower and upper limits of the process
window, parts from all cavities shall meet dimensional and cosmetic requirements and be free of internal
component damage or defects (reference Section 3.3.18 of ES7U5A-2C204-AG or the latest version of this
specification).
(5) Evaluate parts as follows:
• X- ray parts and evaluate for movement on internal components (H-frame or carrier, cable, magnet and
IC)
• Evaluate porosity by cross sectioning the overmold or premold at pre-determined locations and then
observe the sample under magnification.
o Overmold: evaluate for voids in thickest sections of overmold or near sealing ribs
o Carrier: evaluate for voids in locations which experience high loads during overmolding
process
• Visual verification under magnification – verify condition of melt ribs on carrier assembly (profile of
tips)
• Perform functional and sealing tests (reference Thermal Shock Endurance - Section 3.3.1 of ES7U5A-
2C204-AG and EY-0128 or the latest versions of these specifications)
(6) Sampling method for part evaluation
At least one part per cavity molded under each of the following process conditions:
• At upper cavity pressure limit
• At the mid-range of cavity pressure window
• At lower cavity pressure limit respectively
6.2.3 CONFIRMATION RUN
(1) Start up the molding process by using the machine input parameters developed.
(2) Record the number of shots needed at startup for cavity warm-up, scrap these parts, and record on the
control plan or process sheet.
(3) Verify that cavity pressure is at +/- 10% of the mid-point of process window. If not, adjust injection
velocity or hold pressure slightly to make cavity pressure "centered" in process window at startup.
(4) Run 300 shots (for multi-cavity tools, the shot number may be reduced after consulting Ford PD and STA)
and monitor cavity pressure.
(5) Use upper and lower limits of cavity pressure to reject and accept parts (note: the molder should use a
process window narrower than the one established above for quality control purpose in production).
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(6) Evaluation:
• Perform functional testing on all parts
• Investigate the root cause of any defective parts and determine the corrective actions.
• Conduct visual inspection of all parts.
• Select random samples for dimensional evaluation.
• Select random samples for porosity, x-ray, and other evaluations specified by Ford engineering.
6.2.4 PROCESS OPTIMIZATION AND ROBUSTNESS EVALUATION
After the molder has established an initial process and conducted a confirmation run, the molder shall conduct
a full factorial DOE by varying the following process parameters: Injection Speed(s), Hold Pressure(s), and
Barrel Temperature(s). The DOE shall cover a larger variation in parameters than required for production and
include a control group from the mid-point of the process window established in Section 6.2.2. When
evaluating DOE groups, the molder shall consider the product attributes and sealing tests defined in Section
6.2.2.
Note: When conduction DOE, discard appropriate number of shots after changes in process settings or after
any cycle interruptions.
6.2.5 DOCUMENTATION
The molder shall thoroughly document process development and DOE studies, and summarize results and
findings. Retain these documents for the life of the program.
6.3 HIGH FILLER CONTENT MATERIALS
6.3.1 MATERIAL SELECTION AND PART DESIGN
(1) Filler, especially long fiber, is harmful to knitline strength. If knitline strength in the part is a major
concern, avoid selecting materials with high filler content (30% or higher) or take strength reduction into
consideration in the part design.
(2) Reducing wall stock variation is conducive to stronger knitlines. The variation of nominal wall stock shall
be less than 20%.
(3) Consider wear resistant steel for mold, barrel and screw when high wear fiber such as glass fiber is used as
reinforcement in high fiber content material.
6.3.2 MOLD DESIGN AND CONSTRUCTION
(1) Conduct mold flow simulation and explore the impact of gating system and flow leader. Below are the
design guidelines for robust knitlines:
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• Avoid knitlines in high stress areas.

• Locate knitlines on less visible surfaces.
• Increase the meeting angle of two melt fronts. In most cases, a meeting angle of 120o or greater will
tend to minimize surface mark.
• Limit flow distance and avoid significant decrease of temperature at the merging melt fronts. For a
semi-crystalline polymer, the melt temperature of the merging melt fronts shall be no less than 10 oC
above the melting temperature of the material.
• For multi-cavity mold, if knitline forms at the end of fill in each cavity, improve cavity fill balance.
(2) Additional mold features that are conducive to stronger knitlines
• Add vents at knitline locations.
• Use a flow tab at the knitline to ensure knitline strength.
• Use vacuum to enhance venting.
• Use sequential valve gating to minimize the presence of knitlines, especially for exterior and interior
parts with large surface areas and demanding appearance requirements.
6.3.3 MOLDING PROCESS
The following process conditions are conducive to stronger knitlines:

• Form knitlines in the fill stage, rather than pack/hold stage if possible.
• Higher injection speed
• Higher hold pressure
• Higher mold temperature
• Higher melt temperature (use with caution, especially for heat sensitive plastics)
6.4 THERMOSET PLASTICS
General guidelines for part, mold, and process robustness such as wall thickness, cavity balance, and shot-to-
shot consistency for thermoplastic parts are also applicable for thermoset parts. A few items are unique to
thermoset parts.
6.4.1 PART DESIGN
Avoid designing parts that require consistent cosmetic quality at parting line since volatiles generated during
thermoset material molding process often lead to flash at the parting line.
6.4.2 MOLD DESIGN
(1) Thermocouples and Location
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Placement mechanism for mold temperature controlling thermocouples must ensure the consistency of
temperature measurement over long term. In the case of electrically heated molds, the thermocouples should
be located between two cartridge heaters. Whenever possible, the thermocouples should be located at a
distance of 32 to 38 mm from the closest cartridge heater and at a depth of 40 to 50 mm under the mold
surface.
(2) Gates
Unique gate design considerations for the thermoset molding include using wear resistant gate inserts,
considering inserts for area in the cavity opposite to the gate as well as where material fronts impinge, and
avoiding gate depth 1.3 mm or smaller.
(3) Mold Temperature
Minimize temperature difference between one spot of the cavity and another in a single cavity and between
cavities in a multi-cavity mold. As a best practice, the maximum temperature difference between the lowest
temperature spot and the highest temperature spot among all cavities should be 10 oC or less for molding most
thermosets.
(4) Venting
Vent depth in a thermoset injection mold is several times more than that in a thermoplastic injection mold. For
polyester based thermosets, the vent depth is between 0.05 mm to 0.06 mm. Draw-polish the vents in the
direction of flow to the same finish as cavities or cores. Use vacuum venting for parts that are difficult to vent.
The vacuum system should have the capacity to pull a minimum of 21 inch of Hg in the mold.
(1) Material storage

The supplier should store a thermoset material in sealed container at its specified temperature and track its
shelf life. For black bulk molding compound (BMC), the storage temperature is less than 18 oC and the shelf
life is typically one month. In addition, the supplier should reseal opened containers to minimize moisture and
volatile content changes in the compound.
(2) Nozzle temperature
The nozzle must be temperature controlled to maintain a proper balance between the relative cooler barrel
(typically below 90 oC) and the relative hotter mold (typically in excess of 150 oC).
(3) Process monitoring
Cavity pressure is the preferred indicator used in process startup and in-process monitoring. If cavity pressure
sensing is not available, part weight after de-flash may be used as an indicator.
6.5 COLOR AT PRESS
6.5.1 COLORABLE RESIN AND COLOR CONCENTRATE
Guidelines for material and colorant are as follows:
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(1) Thermoplastics such as PP (filled and non-filled), TPO, ABS, PC/ABS, PBT and PA may be colored.
Ford Materials Engineering and Design Quality shall approve color concentrate suppliers for these
applications.
(2) The molder shall use non-abrasive pigments to maintain impact properties in glass fiber or milled glass
reinforced thermoplastics since abrasive pigments such as Titanium Dioxide will cause damage to glass fibers.
As an example, Zinc Sulfide instead of Titanium Dioxide should be used in the coloring of long glass
reinforced PP.
(3) For interior and exterior automotive applications, let down ratios are typically 25-50:1. This means fifty
parts base resin to one part colorant. Higher pigment loading in color concentrate may improve scratch
resistance.
6.5.2 MACHINE AND MOLD FOR COLOR AT PRESS
Guidelines for machine and mold are as follows:

(1) The molder shall use a gravimetric feeder with a paddle mixer for color at press application. In addition,
the molder shall ground the system to minimize color separation due to static charge.
(2) Impact modified resins that contain higher rubber content may require a combination of mixing screws,
mixing nozzles, and mixing heads to ensure homogenous mixing. Consult the raw material and colorant
suppliers for recommendations and assistance.
(3) The molder shall size the machine such that the barrel contains no more than five shots to minimize
material property degradation due to excessive melt residence time.
(4) Consult the raw material and colorant suppliers for technical recommendations and assistance regarding
gate and vent design.
6.6 LONG GLASS FIBER REINFORCED POLYPROPYLENE
A typical long glass fiber reinforced PP pellet is approximately 11 mm long and 3 mm in diameter. Parallel
reinforcing glass fibers run the entire length of the pellet. The glass fibers are impregnated in a PP matrix and
are completely encapsulated. Guidelines for injection molding of long glass fiber reinforced PP are as follows:
(1) The molder shall avoid thin wall design. The minimum wall thickness shall be 2.2 mm.
(2) The molder shall use gravimetric feeders and avoid using mixing screws. The supplier should use screw
type recommended by the raw material supplier.
(3) The molder shall dry the material per the raw material supplier's recommendation prior to molding.
(4) The molder shall follow melt and mold temperature recommendations by raw material supplier.
(5) Color long glass reinforced PP only with non-abrasive pigments.
(6) A practical method for determining fiber length in the finished parts is to use a muffle furnace to burn away
resin, and then visually examine and measure the fiber length under a microscope.
6.7 STORING AND SHIPPING MOLDED NYLON PARTS
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Nylon (PA 6, PA 66) parts may require moisturizing for improved toughness and aid in preventing breakage
during the assembly process. A minimum of 2% moisture is recommended for successful installation. If a 2%
minimum water percentage cannot be achieved, an assessment should be made of the part's ability to be
installed successfully with a lower percentage of water. Parts must stay in the conditioning environment until a
maximum of 24 hours before use.
It is important to note that the addition of fillers in the resin reduces the effects of moisture absorption.
Addition of filler would also minimize unwanted dimensional changes.
6.7.1 RECOMMENDED STEPS FOR CALCULATING MAXIMUM PERCENT MOISTURE CONTENT
(1) Weigh the part on a suitable electronic scale, and record the initial weight.
(2) Place the part and a water-saturated sponge or rag in a sealable polyethylene bag (or equivalent).
(3) After 24 hours, remove the part from the bag and record the weight.
(4) Continue to weigh the part in 24-hour intervals until the weight does not change for three consecutive days.
The part is then considered to be saturated and this is the final weight.
(5) Calculate the percentage of water (by weight) of the part:
(Final Weight – Initial Weight) / Initial Weight x 100% = % Water Absorbed
6.7.2 DESIGNING PARTS TO BE ROBUST TO INSTALLATION/ASSEMBLY IN DRY-AS-MOLDED

(DAM) CONDITION
DAM nylon parts may also be designed to be robust to installation/assembly stresses where the original DAM
properties are maintained.
Impact modified grades of nylon resin (e.g. DuPont Zytel ST801) should be used whenever it is not feasible to
ship components, such as fasteners or snap-on parts, in sealed bags.
6.8 LIVING HINGE
Not to be used in appearance application due to whitening of the hinge line. Living hinges may be used only
for non-visible, service-only hinges.
Not to be used in frequently cycled hinges.
The hinge performance is more robust when it is flexed hot upon ejection from the mold.
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6.9 MUCELL® PROCESS
MuCell® process is a continuous microcellular foam process developed and commercialized by Trexel Inc.
The process involves the controlled use of gas in its supercritical state, known as super critical fluid (SCF) to
create a microcellular-foamed part.
6.9.1 PART AND MOLD DESIGN
In principle, guidelines for injection molding part and mold design recommended in Section 3 of W-IMMS
also apply to parts and molds designed for MuCell® process. Listed below are key items affecting weight
reduction and cell size and distribution:
(1) Use cooling analysis to determine “hot spot” in the part and minimize “hot spot” by introducing
enhanced local cooling in the mold or coring out thick section in the part during design stage.
(2) Conduct mold flow analysis to determine potential gas trap locations and use flow lead and other
means to eliminate gas trap during design stage.
(3) Minimize wall thickness variation and ensure that wall thickness variation is no more than 20%.
(4) Chose gate size such that it is sufficiently small to meet the minimum pressure drop requirement for a
MuCell® process, but large enough to avoid excessive shear through gate during fill stage.
(5) Design molds with sufficient venting capability, especially at the end of fill area and at features such
as ribs and bosses.
(6) Design sufficient radii on features such as ribs and bosses to lessen flow hesitation when melt passes
these features
6.9.2 EQUIPMENT
The molding machine shall be specially designed and manufactured. The molder may also modify standard
reciprocating screw injection molding machine and use it for MuCell® process. The machine must have the
key components to fulfill following unique functions:
(1) A special screw and barrel (with SCF injector) that allow introduction of SCF at critical stage of
plastication, rapid dissolution of SCF into the melt, and formation of single-phase solution.
(2) A nozzle shut-off that maintains the required melt pressure in front of the screw during screw recovery
and during screw idle, as well as provides a positive shut-off between the mold cavity and nozzle.
(3) The machine must be capable of maintaining required pressure on the melt (controlling screw
position) while screw is in idle in plastication stage. If necessary, modify machine control to provide
active screw position control and the required pressure instead of relying on means of passive screw
position control.
(4) The unit must be able to inject at high volume rate to meet minimum pressure drop requirement.
Typically, a standard reciprocating injection molding machine is capable of high injection volume rate.
Super critical fluid (SCF) delivery unit is one of the key components of a MuCell molding system. It must
consistently meter the SCF by mass flow rate at constant SCF pressure. The unit shall have the following
controls:
(1) Delivery Pressure that sets the SCF feed line pressure to SCF injector.
(2) Injector Open Position that controls SCF dosing start by screw position.
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(3) SCF Flow Rate that controls mass flow rate of SCF during dosing.
(4) SCF Dosing Time that, along with SCF flow rate, controls the amount of SCF injected into melt.
Compared with a conventional injection molding process, in addition to SCF injection into the melt during
plastication, MuCell® process depends on foam expansion to pack out cavities. In some cases, a brief hold
stage at low pressure may be used to eliminate short shot at last fill area.
Below is a comparison of key process input variables common to both solid molding and MuCell processes:
Parameters A Typical Conventional A Typical MuCell Process

Molding Process
Barrel/Nozzle/Hot Manifold Temperature T T
Screw RPM R (0.5 - 1.5) R
Back Pressure (MPP in MuCell® process) Pback (1.0 - 2.0) Pback
Fill Rate V (1.5 - 2.5) V
Cushion (V-P Transfer Position is set 0.5” – 1” 0.05 “ – 0.1”
accordingly)
Shot Size L (0.80 - 0.95) L
Clamp Tonnage N (0.4 - 1.0) N
Hold Pressure P 0-P
Hold Time thold 0 - 1 seconds
Cooling Medium Temperature Tmold Tmold
Cooling Time t (0.75 - 1.5) t
Below are guidelines for establishing key process input variables unique to MuCell® process:
(1) SCF Delivery Pressure should be set approximately 200 psi higher than MPP (MuCell Process Pressure).
As a rule of thumb, SCF pressure should drop 50 to 200 psi when SCF injector valve opens at the start of
dosing.
(2) SCF Injector Open Position (screw position at which SCF dosing starts) is set approximately 0.6” (15 mm)
plus cushion.
(3) SCF Flow Time may be initially set to 50 percent of the screw recovery time and then adjusted to dose
during 60 percent to 80 percent of the screw stroke. Typically, SCF dosing is cut off at 80 percent of screw
stroke.
(4) SCF Flow Rate can be calculated as follows,
SCF Flow Rate = (W x %SCF) / (12.6 x t) kg/hr
Where W is shot weight in grams, %SCF is the desired SCF level to achieve good cell structure, and t is
SCF dosing time in seconds. Appropriate SCF level (%SCF) should be determined based on Trexel’s
recommendations and optimized by the molder.
33

Global W-IMMS
6.9.4 CELL STRUCTURE EVALUATION
Cell size and distribution in a part made by MuCell® process shall be evaluated. In addition to sections in the
loading path, three other locations (near gate, middle of the part and the end of fill) should also be evaluated.
Cell size may range from 20 µm to 100 µm in a microcellular injection molded part. Individual cells with cell
size in excess of 100 µm could adversely affect the mechanical performance of the part. If large cells are
detected during cell structure evaluation, it is recommended to assess the effect of large cells in the structure to
short term and long term mechanical performance of the parts.
6.10 NATURAL FIBER REINFORCED POLYPROPYLENE
Compared with glass reinforced polypropylene, natural fiber reinforced polypropylene is susceptible to fiber
damage due to overheating in molding process. Therefore, the melt temperature recommended for molding
natural fiber reinforced polypropylene is approximately 30 oC (55 oF) lower than that for molding glass
reinforced polypropylene. In addition, mixing nozzles are not recommended for molding natural fiber
reinforced polypropylene since they increase the risk of excessive shear heat that would raise melt
temperature. Except for high melt temperature concern, fibers in a natural fiber reinforced polypropylene are
typically not prone to breakage during plastication and fill stages in a molding cycle.
Listed below are molding conditions that help retain mechanical performance of the material in a molding
cycle.
(1) Temperature
Target melt temperature is approximately 190 oC (375 oF). Depending on part and tool details, barrel and
nozzle temperature settings should be between 180 to 205 oC (355 to 400 oF).
(2) Back pressure
Back pressure should be set at 3.5 bar (50 psi) or less.
(3) Injection speed
Avoid excessive injection speed that could lead to not only shear heat, but also uneven fiber dispersion from
the gate. In the severe case of uneven dispersion, the fibers are moved to one end of the part.
(4) Mold temperature
Mold should be warmed to 27 oC (80 oF) to 43 oC (110 oF) before production starts.
Consult the material vendor for technical recommendations and assistance if proposed molding conditions are
different from those listed above.
Fiber content cannot be determined using typical ash content from the TGA since the natural fibers will burn
off. When there is a need to evaluate filler content in a natural fiber reinforced material, please contact material
supplier for recommended procedure.
34

Global W-IMMS
7. CRITICAL RESPONSE LIST
When a Ford supplier encounters plastic part quality issues, the molder should refer to the following list for
proper actions during problem solving.
(1) Scope the Application and the Concern

• Ford Part Number
• Resin Supplier
• Resin Product Code and Trade Name
• Nature of the Concern (warpage, dimensions, etc.)
• Frequency of the Concern (all parts, at start-up, etc.)
Items Below Shall Involve the Resin Supplier
(2) Verify Material Quality

• Resin supplier and material product code
• A certificate of analysis provided by resin supplier
• Resin contaminant analysis
• Regrind usage (If so, the maximum allowable regrind percentage)
• Affected material lot or lots
(3) Verify Molding Conditions

• Drying equipment (if applicable)
• Record of drying parameters and moisture content (if applicable)
• Resin supplier recommended molding equipment (screw type, nozzle)
• Resin supplier recommended processing parameters
• Record of processing parameters for a period covering suspect products and known good products
• Molding equipment (including dryer) and processing parameters (including drying) sign-off by resin
supplier
(4) Verify Post-Mold Conditioning (if applicable)

• Moisture conditioning method
• Temperature and time
(5) Resin Supplier Recommended Actions
35

Global W-IMMS
APPENDIX A1
PLASTIC INJECTION MOLDING PRELIMINARY MANUFACTURING RISK ASSESSMENT
Assessment
MFSOW*
Assessment Low High
No.
Guidelines Cross- Observations / Evidence N/A Recommended Actions

Element Risk Risk
reference
1. PART DESIGN FOR PLASTIC INJECTION MOLDING
1. Provide key requirements for the part (whichever are applicable) and highlight
what are new or different compared with surrogate:
Part (1) Part 3D image; (2) Features that are new or different; (3) Class A surface; (4)
Requirements & Major loading path; (5) Assembly attachement locations; (6) Welding surface; (7)
Historical Surface with special requirements such as sealing etc.
1.1
Concerns
during Launch
and Production 2. List lessons learned from product quality history due to design of the injection-
molded part (e.g. significant fit/finish issues and part breakage experienced during
past launches or in production) and recurrence prevention actions in the design of
new part.
1. Part design conforms to applicable commodity specific design rules that are
1.2 Design Rules
related to manufacturing feasibility of the injection-molded part.
1. The planned material grade meets relavent Ford Material Specification and
conforms to Ford Corporate Resin Strategy.
Note: For specific resin strategy, consult responsible material engineer via "Contact List
by Subject" at Material Engineering SharePoint site below:
https://azureford.sharepoint.com/sites/pd-METS/sitepages/home.aspx
1.3 Material
2. If the material is a new grade or blend, the material property data (including melt
rheology and shrinkage) used in mold flow simulation is available and is established
via testing. In addition, for part with large area of class A surface, molding trial
should be planned on a surrogate with the new grade of material to verify that there
is no concern with appearance issues such as tiger stripes.
1. For parts with large area of class A surface such as IP topper, door trim and
1.4 Texture quarter panel etc., if the selected texture has not been proven on a surrogate part
(Ford or other OEMs), new texture development and prove-out are required.
a 1.1
MFSOW*
No. Assessment Low High
Element Risk Risk
reference
1. Base wall thickness: 2 mm ≤ thickness ≤ 4 mm

Note: On appearance parts, for class A surface with backside features (ribs,
bosses), minimum base wall thickness is 2.5 mm.
Base Wall 2. Base wall thickness variation (across the part): < 20%
1.5
Thickness
3. There is NO localized thinning ( that is, an area with thinner wall surrounded by
areas with thicker walls), especially if the area with thinner wall is critical to function
or appearance quality.
1. For appearance parts made of PP and TPO materials, guidelines for rib thickness
are as follows:
1) Textures that have high hiding power to read-through (e.g. Animal and Technical
texture types with texture depth in excess of 60 microns)
a. Thickness ≤ 40% of base wall
b. Thickness ≤ 45% of base wall (permitting slightly visible read-through)
2) Textures that have medium to low hiding power to read-through (e.g. Stipple
Rib Thickness
texture type with texture depth in excess of 60 microns and Animal and Technical
1.6 on a Flat Base
texture types with texture depth between 30 to 60 microns)
Wall
a. Thickness ≤ 35 % of base wall
b. Thickness ≤ 40% of base wall (permitting slightly visible read-through)
3) Textures have extra low hiding power to read-through or with post molding high
gloss paint application (e.g. Stipple texture type with texture depth 30 microns or lower)
a. Thickness ≤ 30%
2. For appearance parts made of materials other than PP and TPO, refer to industry
guidelines or recommendations from material suppliers.
1. Corner/Edge radius:
≥ 0.5 mm
≥ 0.8 mm (for chrome plated parts)
1.7 Radius ≥ 1 mm (for film insert molded parts)
2. Radius at the base of a rib or boss:

≥ 0.3 mm (≥ 0.5 mm for applications in which impact loading is expected)
1. Draft angle for ribs, snaps, hooks in the direction of draw:

o
≥ 0.5 per side
2. Draft angle for non-textured walls in the direction of draw:

1.8 Draft Angle o
≥ 1 per side
3. Draft angle for textured side walls in the direction of draw:

o o
≥ 1 per side + 1.5 per side per 0.025 mm of texture depth
a 1.2
MFSOW*
Element Risk Risk
reference
2. MOLD FLOW SIMULATION WITH ISOTHERMAL COOLING (WITHOUT COOLING CHANNELS)
Mold Flow
2.1 Analysis 1. List simulation software and mesh type used for the analysis.
Software
1. Gate type, size and quantity are based on either benchmark or a preliminary mold
1.11.1
flow simulation.
2. Gate or the section adjacent to the gate DOES NOT freeze early in the cooling
process.
2.11.2
For example, the frozen layer fraction at the section adjacent to it is 1 and the frozen
layer fraction of sections away from the gate is only 0.7 or less.
2.2 Gate
3. Gate location DOES NOT result in melt flow from thin to thick sections. 1.11.5
4. For TPO material only, melt flow length from each gate is within recommended
limit, especially for materials that are known to be susceptible to "tiger stripes" issue.
1.11.6
In the absence of recommendation from material supplier, 305 mm (12 inches) may
be used as a reference.
5. Gate is not located on a joining surface (especially in the case of ultrasonic 1.11.2
welding or laser welding), class A surface, or other restricted areas. 1.11.3
1. Maximum Shear Rate < Shear Rate Threshold
Note: Shear Rate Threshold should be obtained from material supplier. In the absence
2.3 Shear Rate 2.14.1
of material supplier's input, use the following rule of thumb for shear rate threshold:
20,000 s-1 for TPU, 40,000 s-1 for PC, 50,000 s-1 for ABS, 60,000 s-1 for PA, 100,000 s-1
for PP.
1. There is no air trap at a location that is critical to function of the part.
Examples of location critcal to function:

2.9.3
1) Cross section of a part that is hemetically sealed in a post molding process and
2.4 Air Trap then subjected to pressure in service or during assembly.
2) Surface of a head lamp reflector with optical design
2.9.1
2. There is no air trap on class A surface.
2.9.2
a 1.3
MFSOW*
Element Risk Risk
reference
1. For part that is subjected to stress in service or during assembly, avoid knitlines
on sections with high stresses predicted in CAE analysis, especially if the plastic
material contains reinforcements and additives such as glass fiber or talc.
Note: Exception should only be made when design has factored in degradation of
2.16.4
strength at knitline. Consult material supplier for an estimate. In the absence of material
supplier's input, use following rule of thumb for knitline strength as percentage of bulk
strength:
1) ~ 85% with 10% fiber or talc in the material
2.5 Knitline
2. For part with class A surface, if a knitline ends up on the class A surface, the
1.7.3
location of the knitline shall be reviewed and concurred by Ford Design Quality.
3. Melt front temperature decrease from gate to knitline is 15 oC or less. 2.3.1
4. Predicted maximum cavity pressure at the knitline during pack stage reaches 21
2.16.3
MPa (3000 psi) or more.
1. On the same part, avoid unbalanced fill.

2.1.3
For example, one end of the part is completed filled while the other has unfilled volume
in excess of 5% of the cavity volume.
2.6 End of Fill 2. Melt front temperature decreases from gate to end of fill, the decrease is 15 oC or
2.3.1
less.
3. Predicted maximum cavity pressure during pack/hold stage reaches 21 MPa

2.5.3
(3000 psi) or more.
1. Predicted Peak Pressure at injection location during fill,

≤ 75% of the molding machine system pressure (with runner system) 2.5.1
Peak Pressure
2.7 and Clamp
Force
2. Predicted maximum Clamp Force,
≤ 80% of the molding machine clamp tonnage (with runner system) 2.12.1
a 1.4
MFSOW*
Element Risk Risk
reference
1. Hold time used in the simulation is longer than the predicted gate seal time.
2. Fill, pack, cooling time is estimated. 2.22.1
3. Estimated Cycle Time is 85% of the Planned Cycle Time or less.

Hold Time and
2.8 Note: Estimated Cycle time = (fill time + pack/hold time + cooling time) + Mold Open
Cycle Time
Time. In the absence of surrogate, refer to data below for mold open time:
1) Time for opening and closing mold:
80 to 200 T machine: 4 - 8 seconds; 200 - to 500 T machine: 6 - 10 seconds
> 500 T machine: 8 - 15 seconds
2) Time for part ejection: 0.5 - 2 seconds
3) Time for part removal (e.g. pick up by a robot or drop to a chute)
Small part: 0.5 - 3 seconds; Large part: 3 to 6 seconds
1. Mold temperature used in the simulation is within the range recommended by

material supplier.
Part and Mold
2.9 o 2.7.2
Temperature In the absence of recommendation from material supplier, temperature range ( C)
below may be used as a reference:
ABS: 50 - 80; PP: 30 - 70; PA6: 60 - 90; PMMA: 50 - 80; PC: 60 - 100; POM: 80-100
1. When deflection in X, or Y, or Z direction exceeds the target (default is 2 mm),

1.9.1
contributions to deflection from differential shrinakge, orientation, and differential
1.9.2
cooling are available and main contributor or contributors that lead to excessive
2.18.1
deflection are identified.
2. When deflection in X direction exceeds the target, warpage mitigation actions

have been investigated. The actions may include, but is not limited to, part design,
2.19.1
mold design, process parameters, as well as assembly conditons such as
attachement point, trending positive or negative to rest of the assembly.
Warpage
2.10
Analysis 3. When deflection in Y direction exceeds the target, warpage mitigation actions
have been investigated have been investigated. The actions may include, but is not
limited to, part design, mold design, process parameters, as well as assembly 2.20.1
conditons such as attachement point, trending positive or negative to rest of the
assembly.
4. When deflection in Z direction exceeds the target, warpage mitigation actions

have been investigated have been investigated. The actions may include, but is not
limited to, part design, mold design, process parameters, as well as assembly 2.21.1
conditons such as attachement point, trending positive or negative to rest of the
assembly.
1. Shot weight is estimated. 2.23.1

2.11 Part Weight
2. Estimated shot weight is 20% to 70% of barrel capacity of the planned molding
machine.
a 1.5
MFSOW*
Element Risk Risk
reference
3. MOLD FLOW SIMULATION WITH MOLD COOLING CHANNELS
Mold Flow
3.1 Analysis 1. List simulation software and mesh type used for the analysis.
Software
1. Gating strategy (gate type, size, quantity, and locations) is the same as that in
1.11.1
initial mold flow simulation, that is, mold flow simulation with isothermal cooling.
2. Gate or the section adjacent to the gate DOES NOT freeze early in the cooling
process.
3.11.2
For example, the frozen layer fraction at the section adjacent to the gate is 1, whereas
the frozen layer fraction of sections away from the gate is only 0.7 or less.
3.2 Gate
3. Gate location DOES NOT result in melt flow from thin to thick sections. 1.11.5
4. For TPO material only, melt flow length from each gate is within recommended
limit, especially for materials that are known to be susceptible to "tiger stripes" issue.
1.11.6
In the absence of recommendation from material supplier, 305 mm (12 inches) may
be used as a reference.
5. Gate is not located on a joining surface (especially in the case of ultrasonic 1.11.2
welding or laser welding), class A surface, or other restricted areas. 1.11.3
1. Maximum Shear Rate < Shear Rate Threshold
Note: Shear Rate Threshold should be obtained from material vendor. In the
3.3 Shear Rate 3.14.1
absence of material vendor's input, use the following rule of thumb for shear rate
threshold: 20,000 s-1 for TPU, 40,000 s-1 for PC, 50,000 s-1 for ABS, 60,000 s-1 for
PA, 100,000 s-1 for PP.
1. There is no air trap at a location that is critical to function of the part.
Examples of location critcal to function:

3.9.3
1) Cross section of a part that is hemetically sealed in a post molding process and
3.4 Air Trap then subjected to pressure in service or during assembly.
2) Surface of a head lamp reflector with optics
3.9.1
2. There is no air trap on class A surface.
3.9.2
a 1.6
MFSOW*
Element Risk Risk
reference
1. For part that is subjected to stress in service or during assembly, avoid knitlines
on sections with high stresses predicted in CAE analysis, especially if the plastic
material contains reinforcements and additives such as glass fiber or talc.
Note: Exception should only be made when design has factored in degradation of
3.16.4
strength at knitline. Consult material supplier for an estimate. In the absence of material
supplier's input, use following rule of thumb for knitline strength as percentage of bulk
strength:
3.5 Knitline 2. For part with class A surface, if a knitline ends up on the class A surface, the
1.7.3
location of the knitline shall be reviewed and concurred by Ford Design Quality.
3. Melt front temperature decrease from gate to knitline is 15 oC or less. 3.3.1
4. Predicted maximum cavity pressure at knitline/weldline during pack stage reaches

3.16.3
21 MPa (3000 psi) or more.
1. On the same part, avoid unbalanced fill.

3.1.3
For example, one end of the part is completed fille while the other has unfilled volume in
excess of 5% of the cavity volume.
3.6 End of Fill 2. Melt front temperature decreases from gate to end of fill, the decrease is 15 oC or
3.31
less.
3. Predicted pack pressure at end of fill reaches 3000 psi / 21 Mpa (plastic pressure)
3.5.3
or more.
1. Predicted Peak Pressure at injection location during fill,

≤ 75% of the molding machine system pressure (with runner system) 3.5.1
Pressure and
3.7
Clamp Force
2. Predicted maximum Clamp Force,

3.12.1
≤ 80% of the molding machine clamp tonnage (with runner system)
a 1.7
MFSOW*
Element Risk Risk
reference
1. Hold time used in the simulation is one second or more longer than the predicted
gate seal time.
2. Fill, pack, cooling time is estimated. 3.22.1
3. Estimated Cycle Time is 85% of the planned Cycle Time or less

Estimated cycle time = (Fill + Pack + Cooling) Time + Mold Open Time
Hold Time and
3.8 Where Mold Open Time includes time for mold opening and closing, time for part
Cycle Time
ejection, time for part removal, and delays in between these actions.
Note: In the absence of surrogate, data below may be referenced,

(1) Time for opening and closing mold
80 to 200 T machine: 4 - 8 seconds
200 - to 500 T machine: 6 - 10 seconds
> 500 T machine: 8 - 15 seconds
(2) Time for part ejection: 0.5 - 2 seconds
(3) Time for part removal (e.g. pick up by a robot or drop to a chute)
Small part: 0.5 - 3 seconds
Large part: 3 to 6 seconds
1. Coolant Flow Rate exceeds the recommended threshold for turbulent flow (for
3.7.2
water, Reynolds number > 5000).
2. Coolant temperature increase from inlet to outlet is 3 oC (~ 5 ºF) or less. 3.7.2
3. Mold surface temperature variation (A side and B side) is within the range
recommended by material supplier.
In the absence of recommendation from material supplier, range below may be used as 3.7.2
a reference:
Cooling For amorphous materials, ≤ +/- 10 oC.
3.9 For semi-crystalline materials, ≤ +/- 5 oC.
Analysis
4. Part temperature variation is within the range recommended from material

supplier.
3.7.2
In the absence of a recommendation from material supplier, ≤ +/- 10 oC may be used
as a reference:
5. At ejection, the temperature difference between a "hot spot" on the part and
location away from the "hot spot" is 20 ºC (36 ºF) or less. If the difference exceeds 3.7.3
o
20 C, special cooling methods, including 3D printed conformal cooling inserts, have 3.7.4
been investigated.
a 1.8
MFSOW*
Element Risk Risk
reference
1. Supplier shall identify parts with similar design in recent launches, list specific
dimension and fit issues related to warpage in the part, and countermeasures used 1.9.4
to solve the issues.
2. For parts with dimension or fit issues in the past, supplier shall consider the 3.18.1
following aspects when reviewing warpage results: 3.19.1
(1) Direction of deflection: trending positive or negative to assembly 3.20.1
(2) Distance of concerned deflection to the nearest attachment point 3.21.1
3. For parts with dimension or fit issues in the past, supplier shall identify main
contributors to deflection / warpage results. If the main contributor is differential 3.18.1
cooling, supplier shall revisit the cooling analysis and investigate more "hot spots" 3.7.4
methods.
Warpage
3.10
Analysis
3.18.1
contributors to deflection / warpage results. If the main contributor is orientation
3.17.1
effect, supplier shall review the fiber orientation in the part and investigate
countermeasures.
contributors to deflection / warpage results. If the main contributor is differential 3.18.1
shrinkage, supplier shall review the shrinkage distribution in the part and investigate 3.6.1
countermeasures.
6. If "tool/steel correction" approach is utilized to minimize or eliminate warpage, the

mold maker shall have a track record of successfully implementing this method and
has established a proven procedure of dimensional measurement, data analysis,
and tool modification. The supplier shall add additional tuning loops for warpage
correction in overall tool timing.
a 1.9
Global W-IMMS
APPENDIX A2
MOLD AND MOLDING PROCESS ROBUSTNESS VERIFICATION
Assessment
Assessment
Number
Assessment Low High

Guidelines Observations / Evidence N/A Recommended Actions
item Risk Risk
1. MOLD DESIGN ROBUSTNESS VERIFICATION
1. Mold shall fit into the planned molding machine and backup machine (if
applicable).
2. Mold clamping and locating schemes shall meet machine specification.
3. Mold shall have safety features that prevent mold from closing in the event of
malfunction of one or more mold actions such as slides, lifters, and core pulls.
Mold Structure and 4. Mold shall be designed with the following two features:
1.1 1) Alignment locks to ensure alignment of mold halves and to prevent unwanted
Actions
movement during molding cycle
2) Locking (e.g. positive locking) for mold actions such as slides, lifters, and core
pulls to prevent unwanted movement during molding cycle
5. Mold shall be designed for intended life cycle. At the minimum, the molder shall
have justifications for following items:
1) Tool steel selection
2) Whether to use tool coating selection
3) Whether to use parting line protection plates and main guidings to protect
parting lines
4) Tolerance and durability of purchased components
1. Parting line mismatch shall be designed to meet Ford specification.
1.2 Parting Line

3. Draft angles for stepped parting lines shall be 5º or more unless positive guiding
is used to protect the parting line.
a 2.1
Assessment
Number
Assessment Low High
item Risk Risk
1. Parting line vent size and distribution shall follow guidelines from Ford, or material
supplier, or tooling standard established by the molder or tool shop.
2. Venting shall be planned for gas trap, last fill and knitline locations that are
predicted by mold flow simulation.
13 Venting
3. Venting shall be planned for part details such as screw bosses and ribs,
especially in the case of tall bosses or ribs (height > 15 mm).
4. Venting shall be provided for runner, sprue, and cold slug well (when applicable).
1. For mutlti-cavity molds with eight (8) or more cavities, supplier shall define a
1.4 Cavity Fill Balance strategy to achieve cavity fill balance (e.g. use of "melt flipper" insert, adjustable flow
restrictors).
1. Radius at the base of a core feature shall be designed to minimize stress

concentration, especially if the core feature is located at a location where high
injection pressure is predicted in mold flow simulation.
1.5 Core Feature
2. Core insert shall satisfy two conditions: (1) to prevent orientation shift during by
using poka-yoke; (2) to prevent core looseness in service by fastening mechanism.
1. Pin diameter is 3 mm or larger if the ratio of length to diameter is 50 or more.
1.6 Ejector Pin

2. If a pin can not be located at the intersections of rib to rib or rib to wall, use a flat
ejector pin to provide more contact area for a rib that is 1.5 mm thick or less.
1. For cold runner system, adopt cold slug wells at each intersection in the runner
and end of sprue.
2. For hot runner system with a cold gate adjacent to the class A surface of a part,
unless it is proven not to cause local discoloration near gate on surrogate parts,
1.7 Cold Slug Well adopt a cold slug well to capture potentially colder initial melt.
3. For direct sprue gating into a class A surface, unless it is proven not to cause
local discoloration near gate on surrogate parts or design a feature on the part to
capture potentially colder initial melt.
a 2.2
Assessment
Number
Assessment Low High
item Risk Risk
2. PRODUCTION MOLD ROBUSTNESS VERIFICATION (At Mold Tryout)
1. Crash prevention mechanisms (e.g. limit switches and positive mechanical

2.1 Mold Safety Feature
protections) on the mold are in working order and activated.
1. No signs of insufficient venting such as

(1) Burn mark (diesel effect) at the end of a flow path.
(2) Flashes that occurs on thinner wall section during fill stage.
2.2 Vents
(3) Short shots at the end of a flow path, which may be eliminated by applying
excessive pack and hold pressure.
(4) Oily film buildup on the cavity or near the vents.
1. For a mutlti-cavity mold,

2.3 Cavity fill balance
Fill imbalance between any two cavities ≤ 5% (by volume or weight)
1. No parting line flashes.

2.4 Parting Line
2. Parting line mismatch meets Ford specifications.
1. No parts sticking in the mold.
2.5 Draft Angle

2. No drag marks on surfaces paralle to the line of draw, especially textured
surfaces, during mold opening (for cavity side) or ejection (for core side).
2.6 Radius 1. No sharp edges and coners on the part.
1. No flash due to loose fit.
2.7 Ejector Pin 2. Ejector pins are flush with or slightly under-flush with the steel surface.
3. No pin push on the parts due to ejector pins.
1. Part dimensions are in specification. If one or more dimensions are not in

specification, a corrective action plan is required.
2.8 Part Quality

2. For parts with class A surface, appearance meets requirements. Specifically, if a
new grade of plastic material or a new type of texture is used, confirm that there is
no appearance issues such as "tiger stripes" and "ghosting".
a 2.3
Assessment
Number
Assessment Low High
item Risk Risk
3. MOLDING PROCESS ROBUSTNESS VERIFICATION (At Home-Line Tryout)
1. Melt temperature is within 50% from the center of the melt temperature range
recommened by material supplier.
3.1 Melt Integrity 2. Residence time is less than the maximum residence time recommended by
material supplier
Note: In the absence of recommended maximum residence time, shot size may be
used as an alternative. Guideline: Shot Size = (20% - 70%) barrel capacity
1. For a multi-cavity mold,

Fill imbalance between any two cavities ≤ 5% (by volume or weight)
3.2 Cavity Fill Balance
2. For a part with two or more extremities in a cavity with a single gate,
Fill imbalance between any two extremities ≤ 5% (by volume or weight)
1. Hold time is based on gate seal time,

Hold Time = Gate Seal Time + (0.5 - 2) sec.
Hold Time and 2. For hydraulic machine,

3.3
Pressure PUL - PLL ≥ 500 psi
Where PUL is the maximum pack/hold pressure at which part appearance and
dimensions are acceptable; PLL is the minimum pack/hold pressure at which part
appearance and dimensions are accepted.
1. Variations of part weight and fill time in thirty (30) consecutive shots shall satisfy
Shot to Shot two conditions:
3.4
Consistency (1) Part weight variation ≤ 0.5%
(2) Fill time variation ≤ 0.08 seconds
1. Process window in terms of part weight:

(W UL - W LL) / W > 2%
Where W UL is the average weight of three parts molded at maximum pack/hold
3.5 Process Window pressure with which the appearance and dimensions of the parts meet requirement,
W LL is the average weight of three parts molded at minimum pack/hold pressure with
which the appearance and dimensions of the parts meet requirement, and W is the
average weight of all six parts.
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APPENDIX B
SELECTED PROCEDURES AND METHODS FOR EVALUATING MACHINE AND MOLD

ROBUSTNESS AND DEVELOPING INJECTION MOLDING PROCESS
B1: Selected Procedures for Machine and Mold Robustness Evaluation
B1.1 Residence Time Estimate
B1.2 Cavity Fill Balance Determination
B1.3 Check Ring Repeatability Determination
B1.4 Pressure Loss Determination
B2: Recommended Procedures for Molding Process Development
B2.1 Viscosity Curve and Velocity Linearity Determination
B2.2 Gate Seal Time Determination
B2.3 Cooling Time Estimate
B2.4 Process Window Determination
B3: A Method for Establishing Production Startup Window
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B1 Selected Procedures for Machine and Mold Robustness Verification
B1.1 Residence Time Estimate
The procedure of estimating residence time is as follows:
a. Convert rated barrel capacity to volume (in cm3)

VRated = (WRated ÷ 16 × 453.6 ) ÷ DPS
where WRated is rated capacity in oz and DPS is density of polystyrene in g/cm3 (1.06 g/cm3 may be used if not
provided otherwise).
b. Add hot runner volume to rated barrel capacity if applicable

VTotal = VRated + VHotRunner
where Vtotal is total melt volume and VHot Runner is hot runner volume.
c. Convert actual shot size to volume

V Actual = W ÷ D
where W is part weight (including sprue/runner/gate if applicable) in grams and D is density of plastic
material in g/cm3.
d. Calculate residence time (in seconds)

TRe sidence = (VTotal ÷ V Actual ) × TCycle × k
where TCycle is cycle time in seconds and k is screw geometry constant (k = 1.4 if the screw L/D < 4; k = 2.0 if
the screw L/D > 4).
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B1.2 Cavity Fill Balance Determination
The procedure for determining cavity fill balance is as follows:
a. Verify that the melt temperature and the mold temperature are at the middle of the range determined
during design phase or recommended by the vendor. Set the machine to 95% of the maximum available
pressure from hydraulic system, the pack/hold pressure to minimum, and the hold time to zero.
b. Set a medium screw velocity (e.g. 2 inches/sec.) and a safe transfer position (e.g. 50% cavity fill).
c. Adjust the transfer position such that the cavity or cavities are 85% to 98%% full at the end of a molding
cycle.
d. Mold six shots.
e. Weight the parts, average the data from the six shots for each cavity, and use average as the part weight
of each cavity.
f. Determine cavity balance.
(Wmax − Wmin )
× 100%
Wave
where Wmax is the maximum part weight among the cavities, Wmin is the minimum part weight among the
cavities, and Wave is the average part weight of all cavities.
Note: If a hot runner system is used, the supplier may adjust temperature level on each drop to gain better
cavity fill balance. However, the adjustments should not exceed 2% of the nominal temperature set point.
Cavity balance should be verified each time after preventive maintenance involving the hot runner system.
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B1.3 Check Ring Repeatability Determination
The procedure for determining check ring repeatability is similar to that for determining cavity fill balance
(refer to B1.2).
pressure from system, the pack/hold pressure to zero or minimum (if zero setting is not available) and the
hold time to zero.
c. Adjust the transfer position such that the cavity or cavities are 85% to 98%% full at the end of a molding
cycle.
d. Mold ten shots (short shots).
e. Weigh the shots.
f. Determine check ring repeatability as follows,
( SWmax − SWmin )
Check Ring Repeatability = × 100 (%)
SWave
where SWmax is the largest shot weight, SWmin is the smallest shot weight, and SWave is the average shot
weight.
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B1.4 Pressure Loss Determination
The procedure for determining the pressure drops on a hydraulic molding machine for each melt path is as
follows:
pressure from system, the pack/hold pressure to zero or minimum (if zero setting is not available), and the
hold time to zero.
c. Adjust the transfer position such that the cavity or cavities are 95% to 98% full at the end of a molding
cycle, make one shot, and record the peak hydraulic pressure during fill.
d. Adjust the transfer position such that the melt has just past gate, mold one shot, and record the peak
hydraulic pressure.
e. Adjust the transfer position such that the sprue and runner are filled, make one shot, and record the peak
hydraulic pressure.
f. Make an air shot and record the peak hydraulic pressure.
g. Determine the pressure loss at each stage along the melt flow path and the available pressure to fill the
cavity.
ΔPnozzle = Pf x R
ΔPsprue & runner = (Pe – Pf) x R
ΔPgate = (Pd – Pe) x R
ΔPcavity = (Pc – Pd) x R
Available Pressure = (Ps – Pd) x R
where ΔP items are pressure losses when the melt flows past key positions in the melt delivery system, R is
intensification ratio, Pc, Pd, Pe, and Pf are peak hydraulic pressure values recorded in steps c, d, e, and f
respectively, Ps is 90% of the maximum available pressure from the hydraulic system.
Note: Exact steps in pressure loss determination may be modified to reflect the details of different melt
delivery system.
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B2 Recommended Procedures for Molding Process Development
B2.1 Viscosity Curve and Velocity Linearity Determination
The procedure for determining in-mold viscosity curve and screw velocity linearity for a hydraulic molding
machine is as follows:
during design phase or recommended by the vendor. Set the machine to 95% of maximum available
b. Set a moderate screw velocity (e.g. 2 inches/sec.) and a safe transfer position (< 60% cavity fill).
c. Increase the screw velocity progressively (adjust transfer position to avoid overfill if necessary). At
maximum screw velocity, adjust the transfer position such that the cavity or cavities are approximately 95%
to 98% full at the end of fill, mold one shot, and record the screw velocity, the fill time and the peak hydraulic
pressure.
d. Reduce the screw velocity by 10 to 20%, mold one shot, and record the screw velocity, the fill time and the
peak hydraulic pressure.
e. Repeat step d until the lowest screw velocity possible is reached.
Steps “f” to “g” are for determining in-mold viscosity curve
f. Calculate the relative viscosity and shear rate at each screw velocity level.
Relative Viscosity* = Peak Hydraulic Pressure x Intensification Ratio x Fill Time (psi-sec.)
Shear Rate = 1/Fill Time (1/sec.)
* If an electric machine is used, the multiple of Peak Hydraulic Pressure and Intensification Ratio in the
Relative Viscosity calculation needs be replaced by Plastic Pressure, that is,
Relative Viscosity = Peak Plastic Pressure x Fill Time (psi-sec.)
g. Plot the in-mold viscosity curve (Relative Viscosity vs. Shear Rate).
An example of viscosity curve is shown in Figure 1. In this example, when the shear rate is in excess of
0.65/sec. or injection time is less than 1.5 sec., the process is in the linear region of the viscosity curve and a
change in shear rate only causes a small change in viscosity.
Steps “h” to “j” are for determining screw velocity linearity
h. Calculate Actual Velocity

Assume constant screw velocity,
Actual Velocity = Shot Length / Fill Time (in./sec.)
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where Shot Length is the difference between screw back position and V-P switchover position.
i. Calculate percent Deviation of actual velocity from set velocity
Deviation = ((Set Velocity – Actual Velocity) / Set Velocity) x 100 (%)
j. Plot the screw velocity linearity (compare Actual Velocity vs. Set Velocity)
An example of screw velocity linearity is shown in Figure 2. In this example, actual velocity, set velocity, and
percent deviation are plotted against the shot number (a total of 9 shots, from 90% to 10% of maximum
speed, were used in this example). When screw velocity is in excess of 2 inches/sec., actual screw velocity
lags set velocity appreciably and the deviation of actual velocity from set velocity is close to 12%.
Figure 1 In-mold Viscosity Curve
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4.5 14
4.0
Set Velocity 12
Screw Velocity (In./Sec.)
3.5 (in./sec.)
Velocity Deviation (%)

10
3.0 Actual Velocity
(in./sec.) 8
2.5
2.0 6
1.5
4
1.0
2
0.5
0.0 0
1 2 3 4 5 6 7 8 9
Figure 2 Screw Velocity Linearity
Shot Number
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B2.2 Gate Seal Time Determination
The procedure for determining gate seal time is as follows:
b. Set the screw velocity such that the process is in the linear region of the viscosity curve (refer to B2.1) and
the transfer position (first to second stage transition) such that the cavity or cavities do not exceed 80% full at
the end of a molding cycle.
c. Set the cooling time based on surrogate data.
d. Adjust the transfer position such that the cavity or cavities are approximately 95%-98% full at the end of a
molding cycle. And then adjust the pack/hold pressure to a moderate level such that parts do not show
molding defects due to either insufficient pressure (e.g. short shot) or excessive pressure (e.g. flash).
e. Set the hold time at one second and mold three shots. Then weigh the parts and average the data.
f. Increase the hold time by one second, and mold three shots. Then weigh the parts and average the data.
g. Repeat step f until 2 to 3 seconds after the part weight no longer increases.
h. Plot a graph of average part weight vs. hold time.
i. Gate seal time is defined as the shortest hold time beyond which part weight no longer increase.
An example of gate seal time study (hold time vs. part weight) is shown in Figure 3. In this example, the gate
seal time is between 6 to 7 seconds.
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Figure 3 Gate Seal Time Study
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B2.3 Cooling Time Optimization
The procedure for optimizing cooling time is as follows:

during design phase or recommended by the vendor.
b. Set the screw velocity such that the process is in the linear region of the viscosity curve (refer to B2.1), the
transfer position (first to second stage transition) such that the cavity or cavities do not exceed 80% full at the
end of a molding cycle, the hold time per gate seat time study (refer to B2.2), and the hold pressure in the
middle of the hold pressure window (refer to B2.4). Then adjust the transfer position such that the cavity or
cavities are approximately 95% to 98% full at the end of a molding cycle.
c. Run a single-factor DOE of critical dimensions vs. cooling time.

• Select cooling time levels
• Mold three shots at each cooling time level
• Measure critical dimensions
• Plot a graph of critical dimensions vs. cooling time
d. Identify the shortest cooling time with which all critical dimensions are within specifications, mold 30 shots
at this cooling time, measure critical dimensions, verify that all critical dimensions are within specification,
and determine the process capability of the dimensions designated SC and CC.
e. If step d does not yield a capable process, choose a longer cooling time and repeat the evaluation in step
d.
f. Repeat step e until desired process capability is achieved. The corresponding cooling time is the optimized
cooling time.
Note: Sometimes, if by shifting the means of one or two critical dimensions, a capable process is achieved
with a shorter cycle time, it may be more economical to make a tool correction and use the shorter cycle
time.
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B2.4 Process Window Determination
The procedure for determining operating windows of hold pressure and cavity pressure is as follows:
b. Set the screw velocity such that the process is in the linear region of the viscosity curve (refer to A2.3) and
set the transfer position (first to second stage transition) such that the cavity or cavities do not exceed 80%
full at the end of a molding cycle. Then adjust the transfer position such that the cavity or cavities are
approximately 95% to 98% full at the end of a molding cycle.
c. Set the hold time per results from B2.2 and set the cooling time that ensures sufficient cooling before part
ejection.
d. Progressively increase the hold pressure until parts do not exhibit short shot or sink mark and record the
hold pressure and the peak cavity pressure (or part weight if cavity pressure is not available).
e. Increase the hold pressure by 5 to 10%, mold three shots, and record the hold pressure and the peak
cavity pressure (or part weight if cavity pressure is not available).
f. Repeat step e until right before onset of flash, ejection difficulty, or emergence of other process issues.
g. Measure key dimensions of the molded parts and identify the lowest hold pressure at which both
dimensions and part appearance meet requirements. This will be the lower hold pressure limit.
h. Measure part dimensions and identify the highest hold pressure at which both dimensions and
appearance of the parts meet the requirements. This will be the upper hold pressure limit.
i. Peak cavity pressure is used to define the process window. Thus, the peak cavity pressures corresponding
to the lower and upper hold pressure limits are the lower and upper limits of the process window. If the mold
does not have cavity pressure monitoring capability, part weight is used for process window.
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B3 A Method for Establishing Startup Window
The procedure for establishing startup window is as follows:
a. Review the process window (in terms of cavity pressure profile, or peak cavity pressure, or part weight, or
an equivalent) established during molding process development.
b. Use middle 30% of the process window as an initial startup window.
c. Verify start-up window in production
The initial startup window should be verified in production. In five or more production runs, set up process
condition such that the process starts within the initial startup window (e.g. in terms of part weight). In each
run, collect five or more data points (part weight) and calculate the maximum within-run variation. There are
several scenarios:
i) Maximum within-run variation is 25% or less of the process window.

Conclusion: The startup window may be the same as or wider than the initial startup window.
ii) Maximum within-run variation is between 25% and 30% of the process window.
Conclusion: The startup window may be the same as or narrower than the initial startup window.
iii) Maximum within-run variation is between 30 and 35% of the process window.
Conclusion: The startup window may the same as or narrower than the initial startup window, but at the
same time, a closer process monitoring is required.
iv) Maximum within-run variation is 35% or more of the process window.

Conclusion: A viable startup window can not be established and improvements (part design, tooling, and
process) are needed to widen the process window or reduce process variation.
The graph below illustrates the relations among startup window, within-run process variation and process
window.
Based on the data, one can then stay with the initial startup window, reduce the initial startup window, or
increase the initial startup window for long-term production.
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Upper Process Limit
Maximum
Maximum within-run
Maximum
within-run process
within-run
process
≤ 25% Δ process 25 - 35% Δ variation ≥ 35% Δ
variation
variation
Δ Centerline Startup Window Startup Window Startup Window

Good ≥ 30% Δ Acceptable ≈ 30% Δ Not Acceptable < 30%Δ
Maximum
Maximum Maximum
within-run
≤ 25% Δ within-run 25 - 35% Δ within-run ≥ 35% Δ
process
process process
variation
variation variation
Lower Process Limit
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APPENDIX C
RECOMMENDED METHODS AND FREQUENCIES FOR IN-PROCESS MONITORING
Recommended methods and frequencies of in-process monitoring are as follows:
Category Item Instrument or Method Minimum Monitoring

Frequency
Process Status Moisture content (when A moisture analyzer Startup, material lot
applicable) change, and beginning of
each shift
Process Status Peak cavity pressure (if A cavity pressure monitoring 100%
available) unit
Process Status Part weight (if cavity A balance that has adequate Startup, material lot
pressure monitoring is not resolution and can detect change, and beginning of
available) 0.1% change in part weight. each shift
Process Status Fill Time Data from control panel of the Startup, material lot
molding machine change, and beginning of
each shift
Process Status Screw recovery time Data from control panel of the Startup, material lot
molding machine change, and beginning of
each shift
Process Status Cushion size or screw Data from control panel of the Startup, material lot
position at the end of hold molding machine change, and beginning of
each shift
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APPENDIX D
EVALUATION TOOLS FOR COMPARING PRODUCTION PARTS TO

MINIMUM APPEARANCE STANDARD AAR
Proper lighting and experience is recommended to evaluate production parts against the Minimum Appearance
Standard part. The below items/tools are typically used.
• Ford Corporate Color Master (or Studio Master SM)
• Ford Corporate Texture Master
• AAR Final Appearance Sign-Off Part
• “Macbeth” light
• Sun Gun
• Sunlight (preferred tool, and typically best between 10am – 2pm)
• Spectrophotometer (acquired for reference only, continuous monitoring of process parameters)
• Texture Magnification Loupe
• Gloss Meter (as reference and does not always represent the human eye)
• ATC Orange Peel Masters (can “appear” different on separate colors)
Trained assembly Operators (or sub-assembly operators), Quality Control Inspectors, Color Lab Technicians,
etc. should carefully evaluate production parts. When evaluating color or gloss or both, as well as other
appearance aspects, mechanical monitoring and the human eye may deliver two different results. If ever in
doubt, contact the Ford Design Quality department. If the part visually appears acceptable but measures
outside the acceptable range, or vice versa. Evaluation by a Ford Design Quality representative supersedes
that of any other and any mechanical/gauge measurement.
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APPENDIX E
W-IMMS COMPLIANCE CHECKLIST
Assessment
Expectation Requirements or Not

Observations N/A Satisfactory Recommended Actions
Number Recommended Best Practices Satisfactory
1. PLASTIC PART AND MOLD DESIGN (W-IMMS Section 3)
The molder shall use Appendix A1 "Plastic Injection Molding Preliminary Manufacturing Risk Assessment" in W-
IMMS to assess manufacturability of injection-molded plastic parts based on part design knowledge, quality history
of surrogates, and mold flow simulations during design stage.
The molder shall use Appendix A2 "Mold and Molding Process Robustness Verification" to assess the robustness
1.1 of production mold and molding process during mold and process tryouts.
Note 1: If one or more high risk items are identified during an assessment, the team (supplier or suppliers, Ford PD
and STA) shall plan and implement risk mitigation actions.
Note 2: If the molder elects to use alternative assessment tools, the assessment tools shall be reviewed and
concurred by Ford STA ahead of time.
The molder shall have a product development system that covers part design, mold design, mold construction, and
mold tryout. Refer to Section 3.2 "Part and Mold Design for Manufacturing" for a list of steps in a recommended
system.
For the design of part and mold, the molder shall follow applicable standard or design rules that are specified, or
1.2 recommended, or concurred by Ford Motor Company.
If responsible for part design, unless otherwise specified by Ford engineering, the molder shall verify material
selection by using material data or benchmark to ensure that the material has the necessary material compatibility,
chemical and environmental (temperature, humidity, weathering) resistance, toughness and other physical and
mechanical properties to meet design intent.
The molder shall have a lessons learned system that captures quality history of the commodities and document
quality issues (during launch or in service) related to the design of injection-molded part or mold.
The molder shall conduct mold flow simulations, first without cooling channels and then with cooling channels in
conjunction with mold design.
1.3
The molder shall also use the simulation tool to investigate design improvement actions when needed. For
example, If unacceptable level of warpage is predicted in a part that is prone to warpage-related quality issue, the
molder shall investigate the main factor or factors that cause the warpage and explore mitigation options in part
design, mold design, and processing.
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2. INJECTION MOLDING PROCESS DEVELOPMENT (W-IMMS Section 3)
The molder shall have a system to document (and maintain records) process input variables and key process
2.1 output variables during process development. Refer to W-IMMS subsection 3.3.1 "Key Process Variables" for a list
of variables.
During process development, the molder shall verify that the melt temperature is within the range recommended by
2.2 material supplier and the melt residence time does not exceed maximum residence time specified by material
supplier. Refer to W-IMMS subsection 3.3.2 for more details.
During process development, the molder should establish process input variables by adopting Scientific Molding
approach. Refer to W-IMMS subsection 3.3.3 "Establishing Key Process Input Variables" for how to establish
following process input variables:
a. Temperature settings for barrel, nozzle, and hot manifold (if applicable)
b. Screw RPM and back pressure during plastication
2.3
c. Fill rate (or screw velocity) or rate profile during fill
* The molder shall avoid "pressure-limited" fill by setting pressure sufficiently high during fill
d. V-P switchover position
e. Pack and hold pressure and time
f. Cooling water temperature and cooling time
During process development, the molder shall establish a process window in term of cavity pressure profile or peak
cavity pressure, or part weight (if cavity pressure is not available), or an equivalent (if cavity pressure is not
available and part weight is not feasible due to excessive material density variation).
Once the process window is determined, the molder shall define an initial production startup window around the
2.4 middle of the process window developed. Refer to W-IMMS subsection 3.3.4 for details.
Note: An example of an equivalent process indicator is "torque to fail" value of a critical screw boss feature on an
injection molded part made of 60% glass filled resin. Due to high glass content, variation of material specific gravity
within the same material lot may be too large. Consequently part weight may not correlate with cavity pressure (thus
dimension) well and it may not be used as an process indicator.
During process development, the molder shall determine or confirm procedures for production startup. The
procedures shall include, but not be limited to,
2.5
a. Heat soak time for machine and mold (barrel, hot manifold if applicable, and mold halves)
b. The number of initial full shots scraped before taking "first piece" sample
3. MACHINE ROBUSTNESS (W-IMMS Section 3)
When selecting molding machines for all new Ford products, the molder shall verify that the molding machines meet
the following requirements:
a. Control and monitor pressure in hydraulic cylinder (for hydraulic molding machines). Pressure transducer has
a resolution of 50 psi at the minimum in the operating range.
b. Control and monitor screw velocity. The deviation of actual velocity from set velocity is 20% or less in the
3.1
operating range.
c. Control and monitor screw stroke. Position transducer has a resolution of 0.2% of the full stroke at the
minimum.
d. Control and monitor time. The timers have a resolution of 0.05 seconds at the minimum.
e. Monitor fill time, peak pressure, cushion size and cycle time during production.
The molder shall ensure that the check ring functions properly by conducting "Check Ring Repeatability Test" or an
alternative evaluation on newly installed machines and existing machines after long term preventive maintenance.
Appendix B of W-IMMS (B1.3) provides a frequently used "check ring repeatability test" method. Acceptabe
criterion of check ring leakage in "check ring repeatability test" is 3% or less.
3.2
Check ring leakage verification frequency for existing molding machines shall be as follows:
a. After a check ring assembly repair or replacement event
b. As a long-term preventive maintenance action. The frequency of this action may be determined by the
molder, but should not be less than once every two years.
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For hygroscopic materials such as Nylon and Polycarbonate, the molder shall use a regenerative desiccant type
dryer.
The molder shall select a dryer that has sufficient capacity so that material dwell time meets material vendor
3.3
recommendation.
During process development, the molder shall also determine the minimum material level in the dryer to ensure
sufficient dwell time in a continuous molding operation.
4. PROCESS CONTROL AND MONITORING (W-IMMS Section 4)
The molder shall have a documented process specification (process setup) for key process input variables. Refer
to W-IMMS subsection 3.3.1 "Key Process Variables" for the list of process input variables.
4.1 If the molder plans to use two or more molding machines for one mold and its capacity mold or molds, the process
specification for key process input variables on each machine shall be adjusted such that melt temperature, plastic
pressure, and melt flow rate remain consistent from one machine to another unless the molding machines are
identical.
The molder shall standardize startup routine procedure that includes, but is not limited to, the following details:
a. Heat soak (barrel, hot manifold if applicable, and mold halves)
b. Opening slide gate on the hopper
c. Screw RPM during initial charging
4.2
d. Purging
The molder shall also include in the startup procedure mold-specific items. For example, number of discarded initial
full shots (after short shots, but before taking "first piece" sample).
At production startup and restart, and in-process material lot change, the molder shall verify the following items:
a. Temperature and flow rate of cooling water or other cooling medium - For startup
b. Material type and grade - For startup and in-process material lot change
c. Moisture content (when applicable) - For startup, restart, and in-process material lot change
4.3
d. Key process input variables (per process specification) - For startup
e. Barrel purging - For startup, restart, and in-process material lot change (whe applicable)
f. Cavity and vent cleaning - For startup
g. No gate blockage (for molds with two or more valve gates) - For startup and restart
At production startup, restart, and in-process material lot change, the molder shall verify that the molding process is
within the established startup window.
4.4
Note 1: Molding process "startup window" described here is in terms of cavity pressure profile, or peak cavity
pressure, or part weight, or an equivalent indicator.
Note 2: For large molds, startup verification may be repeated once cavity temperature stabilizes.
A molder shall monitor process outputs that include key process output variables, part appearance, and part
dimensions during a production run. Key process output variables include:
a. Moisture content (if applicable)
b. Fill time
c. Peak hydraulic pressure (for hydraulic machines)
d. Cushion size
e. Screw recovery time
f. Cycle time
4.5 g. Cavity pressure (part weight if cavity pressure monitoring is not available, or an equivalent indicator if cavity
pressure monitoring is not available and part weight monitoring is not feasible)
Note 1: Recommended minimum monitoring frequency for key process output variables and critical or significant
part dimensions is once every 8 hours. Refer to Appendix C "Recommended Methods and Frequencies for In-
process Monitoring" for details.
Note 2: Recommended minimum sample size and frequency for appearance monitoring: 1) One part for each
inspection; 2) Before and after each color change, material change, or process condition change; 3) Every 8 hours
for longer production runs without any changes
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To develop an effective instruction for first piece and last inspection, the molder shall use a systematic approach to
identify and document potential molding defects that would lead to functional failure in assembly or sub-assembly.
The molder shall also identify part features formed by weak mold components (such as a small core pin) that are
susceptible to damage without detection during production. The molder shall document these potential missing
features in the inspection instruction.
4.6
The molder should document locations of these potential molding defects and missing features with the aid of a
sketch or a picture and label each location with an alphabet or a number. The molder should also specify inspection
sequence.
The molder shall prioritize identified potential molding defects and missing features that could lead to functional
failure in assembly or sub-assembly in First and Last Piece Inspection Work Instruction.
The molder shall conduct first and last piece inspection per inspection instruction established.
First piece inspection covers prioritized molding defects, dimensions, appearance, as well as presence of features
4.7
(when applicable).
Last piece inspection covers prioritized molding defects, appearance and presence of features (when applicable).
When one or more key process input variables are changed in the middle of a production run, the molder shall
follow first piece inspection instruction to confirm part quality. The molder shall also confirm that the molding
process is still within the startup window.
Note 1: Key process input variables include, but are not limited to:
4.8 a. All temperature settings
b. Screw RPM and back pressure
c. Injection speed
d. V-P crossover position
e. Pack (and Hold) time and pressure
f. Cooling time
When a Supplier Request for Engineering Approval requires PV testing and the molder specifies a maximum
amount of regrind usage in the molding process, PV samples shall be molded by using the specified maximum
amount of regrind.
4.9
When a Supplier Request for Engineering Approval involves change of supplier or manufacturing site, the molder
shall verify the plastic material used at the new supplier or at the new manufacturing site against the signed-off Bill
of Material.
Before a capacity mold or a refurbished mold is put into production, the molder shall complete assembly trial runs
4.10
and dimensional layout before delivery of production parts.
The molder shall use material identification labels throughout the molding system including:
a. Containers for in in-process material storage that feeds the hopper during a production
b. Containers for holding material that is left in the hopper at the end of a production run
c. Containers for transporting material that is left in the hopper or in-process storage at the end of a production
run
4.11
When handling materials, whether before production, in production, or after production, the molder shall verify the
materials by matching material label with that on the work order or on the destination material storage or both.
The molder shall quarantine resins and colorants without proper material identification labels.
An injection-molded part in sub-assembly delivered to Ford assembly plant shall be traceable to its molding cavity (if
applicable) and week of production,at the minimum, along with material lot, and processing condition.
4.12
In the case that date marking on individual part is not feasible, traceability may be established for each molding lot
by sub-assembly label with molding lot identification code as molded parts are assembled.
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5. MOLD AND MACHINE PREVENTIVE MAINTENANCE (W-IMMS Section 5)
The molder shall have a preventive maintenance program for production molds. The preventive maintenance
program shall cover both short-term and long-term preventive maintenance needs.
5.1
The molder shall establish the list of preventive maintenance items and frequencies based on benchmarking,
recommendations from tool shop, and historical data of the same or similar type of molds.
The molder shall identify all moving components and non-permanent features such as ejectors, core pins, and other
locations that are susceptible to damage and wear on each new mold.
5.2 The molder shall verify the integrity of these potential “maintenance trouble” locations before or after each
production run. In the case that it is not feasible to verify the integrity of a "maintenance trouble” location directly
without disassembling the mold, the molder could assess it indirectly based on the quality of corresponding
locations on the molded part.
The molder shall have a system in place to record process changes made during a production run to correct a
molding quality issue. The responsible process personnel should mark the parts from the last shot before making
process change and hold them until the responsible maintenance personnel has reviewed both mold and parts.
5.3 The system shall alert maintenance personnel the emerging molding quality issue at the end of the production run.
The responsible maintenance personnel (and process personnel) shall review the marked parts before process
change, inspect the suspect location(s) on the mold, determine whether mold issue has led to the process change,
and plan and implement corrective actions in preventive maintenance.
The molder shall have a preventive maintenance program for molding machines. The preventive maintenance
program shall cover both short term and long-term maintenance needs.
5.4
The molder shall establish the list of preventive maintenance items and frequencies based on recommendations
from machine vendors and historical data from the same type of machines.
The molder shall identify spare part needs for critical components on all production molds and molding machines
5.5 (as well as other equipment and measuring devices). At the minimum, the molder shall have spare parts on site
based on availability, lead-time and the impact to delivery of products to Ford Motor Company.
6. ADDITIONAL GUIDELINES FOR SPECIAL APPLICATIONS AND PROBLEM SOLVING (W-IMMS Sections 6 and 7)
The molder shall also follow guidelines if one or more of its molding processes are listed in Section 6 "Additional
6.1
Guidelines for Special Applications".
The molder should use Section 7 "Critical Response List" for recommended problem solving actions when
6.2
encountering plastic part quality issues.
Note:
1) The word "SHALL" is used to indicate a requirement in W-IMMS. The molder needs to take immediate actions to address any area that is not in compliance with the requirement.
2) The word "SHOULD" is used to indicate a recommended best practice only.
e5

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Global W-IMMS

Manufacturing Sixth Edition

FORD GLOBAL MANUFACTURING STANDARD

CONTROL OF PLASTIC INJECTION MOLDING PROCESSES

Copyright © 2022 Ford Motor Company. All rights reserved.

Plastic Injection Molding Technical Club

Copyright © 2022 Ford Motor Company. All rights reserved.

Date Version Major Changes

Copyright © 2022 Ford Motor Company. All rights reserved.

Copyright © 2022 Ford Motor Company. All rights reserved.

2. GENERAL REQUIREMENTS …………………………………………………………………. 9

3. PART, MOLD, MACHINE, AND PROCESS ROBUSTNESS EXPECTATIONS ……………. 10

4. PROCESS CONTROL AND MONITORING EXPECTATIONS ………………………….….. 15

5. MOLD AND MACHINE PREVENTIVE MAINTENANCE EXPECTATIONS …………..….. 21

6. ADDITIONAL GUIDELINES FOR SPECIAL APPLICATIONS …………………………...… 24

Copyright © 2022 Ford Motor Company. All rights reserved.

6.2 SENSOR OVERMOLDING …………………………………………………………..….…. 25

7. CRITICAL RESPONSE LIST …………………………………………………………………... 35

A1: PLASTIC INJECTION MOLDING PRELIMINARY MANUFACTURING RISK

A2: MOLD AND MOLDING PROCESS ROBUSTNESS VERIFICATION ……………………. a 2.1

B: RECOMMENDED PROCEDURES AND METHODS FOR EVALUATING MACHINE

C: RECOMMENDED METHODS AND FREQUENCIES FOR IN-PROCESS MONITORING

D: EVALUATION TOOLS FOR COMPARING TO MINIMUM APPEARANCE STANDARD

E: W-IMMS COMPLIANCE CHECKLIST ..................................................................................... e1

Copyright © 2022 Ford Motor Company. All rights reserved.

1.1 GENERAL DESCRIPTION

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1.2 APPLICATIONS AND LIMITATIONS

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2.1 ENGINEERING AND PROCESS SPECIFICATIONS

2.2 APPEARANCE APPROVAL STANDARD

2.3 CONTROL PLAN

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3. PART, MOLD, MACHINE AND PROCESS ROBUSTNESS EXPECTATIONS

3.1 PLASTIC INJECTION MOLDING MANUFACTURING RISK ASSESSMENT

3.2 PART AND MOLD DESIGN FOR MANUFACTURING

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3.3 INJECTION MOLDING PROCESS DEVELOPMENT

3.3.1 KEY PROCESS VARIABLES

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3.3.2 MELT TEMPERATURE AND RESIDENCE TIME VERIFICATION

3.3.3 ESTABLISHING KEY PROCESS INPUT VARIABLES

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3.3.4 ESTABLISHING PROCESS WINDOW, STARTUP WINDOW, AND STARTUP PROCEDURE

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3.4 MACHINE ROBUSTNESS

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4. PROCESS CONTROL AND MONITORING EXPECTATIONS

4.1 PROCESS SPECIFICATION (SETUP SHEET)

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4.3 PROCESS STARTUP

4.3.1 STARTUP AND SHUTDOWN PROCEDURE

4.3.2 RESTART AND IN-PROCESS MATERIAL CHANGE PROCEDURE

4.3.3 STARTUP VERIFICATION

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• Barrel purging – For startup and restart

4.4.1 MONITORING OF PROCESS CONDITIONS

4.4.2 MONITORING OF PART APPEARANCE

Production Part Appearance

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Refer to Appendix D “Evaluation Tools for Comparing to Minimum Appearance Standard”.

Sample Size and Frequency

4.5 FIRST AND LAST PIECE INSPECTION

4.5.1 FIRST AND LAST PIECE INSPECTION WORK INSTRUCTION

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In the last piece inspection, the molder should verify

4.6 PROCESS CHANGES

4.7 LABELING, VERIFICATION, AND TRACEABILITY

4.7.1 Material Labeling and Verification Within Molding System

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4.7.1 Traceability of Injection-molded Parts

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5. MOLD AND MACHINE PREVENTIVE MAINTENANCE EXPECTATIONS

5.1 SHORT-TERM AND LONG-TERM MOLD PREVENTIVE MAINTENANCE

5.2 MOLD SPECIFIC PREVENTIVE MAINTENANCE

5.3 DETECTION OF EMERGING MOLD MAINTENANCE NEEDS

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5.4 MACHINE PREVENTIVE MAINTENANCE