The objective of this work was to develop a numerical simulation tool that is able to predict the processing window for thin-wall plastic parts made by the injection molding process. This performance predictor links the processing conditions (filling time, resin inlet melt temperature, and so on) to the mechanical properties and failure mechanisms of the part, using empirical data developed for the thermal and shear degradation behavior of the resin. Usage of such a performance predictor will help to expedite the long process development cycle time and to reduce the potentially expensive tooling costs associated with the thin-wall segment of the plastics business.

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