Quality Diagnostics · D02
Weld lines are nearly unavoidable in dense hole-array parts - the real question is where they land, and whether they can be moved off the critical area.
Weld Line
Symptom: where two flow fronts meet, the interface has lower strength than the surrounding body. In dense hole-array parts, every hole is a weld point. It requires feeding with good melting properties and appropriate injection molding conditions to match.
| Weld-Line Location | Risk |
|---|---|
| On an A-grade cosmetic face | May be visible, affects appearance - gate plan must avoid it first |
| In an assembly load-bearing zone | Reliability risk - full CT inspection recommended |
| In a non-functional zone | Acceptable - confirm at the DFM stage |
Use Moldflow simulation to predict weld-line location during gate-plan design, and proactively move the weld zone to a non-load-bearing, non-cosmetic area.