Injection Molding Process Sheet Template
A process sheet is the record of how a mold was proven out on a specific press with a specific resin lot. Fill in the fields, review the document and export it to PDF or Word for the job folder or the press side clipboard.
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Injection Molding Process Sheet Template
Injection Molding Process Sheet
Company: Acme Molding Inc Part number: HSG-2204-A Mold: M-0417 Press: Press 12 (220 ton) Resin: PA66 GF30, black Date validated: 2026-10-20
Material Preparation
Drying: 4 hours at 80 C, dew point -40 C
Temperatures
Barrel: Nozzle 290 C, Z3 285 C, Z2 280 C, Z1 270 C, Feed 60 C Mold: Fixed half 80 C, moving half 80 C
Injection and Pack
Injection: 3 stage, 60 / 40 / 25 mm/s, limit 1400 bar Pack and hold: 700 bar for 3 s, 450 bar for 5 s Cushion and transfer: Cushion 5 mm, transfer at 12 mm
Timing
Cooling 14 s, total cycle 31 s
Verification Shots
| Shot group | Part weight | Key dimension | Visual result |
|---|---|---|---|
| First 5 shots | |||
| After 30 min | |||
| After 2 hours |
Process Notes
Gate freeze verified by weight versus hold time study. Vent cleaned each 4 hours.
Approvals
Record the settings that were validated, not the ones you hope to run. If your customer requires a documented process window, add the high and low limits next to each value before you sign.
Get process sheets into your ERP routing
Optional: we can review how your molding settings are stored and suggest a controlled structure.
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How to use this template
Fill the header, then enter the settings exactly as they were running when the molder signed off the first article. Keep the units consistent with your press controller display so a technician can compare the sheet to the screen without converting. Print one copy for the press and store the signed copy with the mold history so the next setup starts from a known good point.
- Capture settings at the end of validation, not at the start
- Use the same units as the controller screen
- Attach the first article report to the same job
- Revise the sheet whenever the process changes
What a good process sheet contains
A useful sheet covers material preparation, barrel and mold temperatures, injection speed profile and pressure limit, transfer position, pack and hold profile, cooling time and the resulting cycle. Scientific molding practice adds a viscosity curve, a gate seal study and a pressure drop check. You do not need all of these on one page, but the transfer position and the pack profile are the settings most often lost when a mold moves between presses.
- Material drying time, temperature and dew point
- Zone temperatures from feed throat to nozzle
- Fill speed profile and injection pressure limit
- Pack and hold pressure and time
- Cushion and transfer position
Moving a mold between presses
Presses differ in screw diameter, check ring behavior and hydraulic response, so a sheet from press A is a starting point on press B and not a copy and paste. Match shot size as a percent of barrel capacity, then re-establish transfer position with a short shot study. Write the second press result on a new sheet and link both to the same mold ID.
- Keep shot size within roughly 20 to 80 percent of barrel capacity
- Check the clamp tonnage margin on the new press
- Repeat the gate seal study
Common mistakes
The most common mistake is recording only the setpoints. Actual values, such as peak cavity pressure or fill time in seconds, tell you whether the process is stable. The second is skipping the revision date, which makes it impossible to know whether a sheet reflects the current resin grade or a previous one. The third is storing sheets in a personal folder rather than with the mold record.
Frequently Asked Questions
Is this the same as a scientific molding data sheet?
It covers the same core settings, but a full scientific molding package also includes viscosity, pressure drop and gate seal studies. Use this as the controlled summary and attach the study results as supporting records.
How often should the sheet be revised?
Revise it whenever a setting, resin grade, mold modification or press changes, and at each requalification. Always date and sign the new revision so operators know which one is current.
Can I export it to Excel?
Yes. The page exports to PDF, Word and Excel automatically, so you can keep a copy in whichever format your quality system uses.
Does it replace a control plan?
No. A control plan defines what is checked and how often. The process sheet records the settings that make the part. They work together, and many customers expect both.
If your mold and process records live in an ERP or MES, we can help you pull them into a controlled routing or work instruction instead of loose sheets.
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