Achieving a process window wide enough to ensure consistent part quality depends on achieving sufficient pressure at end of fill. FIG 1 As an example, this automotive A-pillar is molded of a PC/ABS or PC/ASA alloys, so its viscosity is relatively high to start with. Good mold design, a capable molding machine, and a suitable process will be required to achieve a “safe” process window. FIG 2 Sequential valve gating is one way to minimize the ratio of flow length to wall thickness in order to broaden the process window. FIG 3 In a machine equipped with a hydraulic pressure sensor and a mold fitted with cavity-pressure sensors at the EOC, the eDart data from a 15-hr production run show how EOC pressure decreases in proportion to the increase in resin viscosity. Ever encounter a part that has a process window thinner than a human hair? Managing the pressure loss in the molding process is complicated and influenced by many factors that are outside the control of the molder. We must evaluate each of the following areas to ensure that the molder has a wide process window. Ultimately, the success of molding starts at the OEM. No matter the environment or application, a design engineer ...