Molding Process Window Study Record Template
A process sheet records the settings that make good parts on a particular mold and press, so the next setup starts from a known point. This template gives you a clean printable sheet with the essentials and blank zones to fill in at the machine.
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Molding Process Window Study Record Template
Molding Process Window Study Record
Company: Acme Plastics Ltd Part: PN-30417 - Housing cover Mold: M-1182 (4 cavities) Machine: Press 14, 200 ton Date: 2026-10-20
Material and Drying
Resin: PP copolymer, MFI 20 Resin lot: L-55120 Drying temperature: Not required Drying time: Not required
Key Process Settings
| Parameter | Setting | Actual | Initials |
|---|---|---|---|
| Melt temperature | 230 deg C | ||
| Mold temperature | 40 deg C | ||
| Injection pressure limit | 120 bar | ||
| Hold pressure | 55 bar | ||
| Hold time | 5.0 s | ||
| Cooling time | 11.0 s | ||
| Shot size and cushion | 62 mm, cushion 6 mm | ||
| Total cycle time | 22.5 s |
Barrel and Nozzle Zones
| Zone | Setpoint | Actual |
|---|---|---|
| Feed throat | ||
| Zone 1 | ||
| Zone 2 | ||
| Zone 3 | ||
| Nozzle | ||
| Hot runner / manifold |
Process Window Trials (low, nominal, high)
| Parameter varied | Low | Nominal | High | Result (parts good / bad) |
|---|---|---|---|---|
| Melt temperature | 230 deg C | |||
| Mold temperature | 40 deg C | |||
| Hold pressure | 55 bar | |||
| Hold time | 5.0 s | |||
| Cooling time | 11.0 s |
Notes
Check vents every 4 hours. Regrind up to 15 percent allowed. Record cushion at start of each shift.
Approvals
A starting point for your own controlled document. Add your document number, revision and any fields your customer or quality system requires. Settings shown are examples, not recommendations.
Link process sheets to molds in your ERP
Optional: we can review how mold and routing records are held in your ERP and where process data could attach.
Optional. The tool and every export work without this. No spam.
How to use it
Fill the header fields for part, mold, machine and resin, then enter the approved settings. The Actual column and zone table are left blank for the technician to complete at setup or each shift. Export to PDF or Word for the press-side binder, or to Excel to build a library of approved processes by mold. Update the revision whenever settings change and keep old versions.
What to record
The critical items are material and drying conditions, melt and mold temperature, injection pressure limit, hold pressure and time, cooling time, shot size and cushion, and total cycle time. Add injection speed profile, back pressure, screw rpm, decompression, ejection settings and hot runner temperatures where your process depends on them. Scientific molding practice also records fill time and transfer position.
- Use units on every value, such as bar or psi, mm or inches
- Record the cushion since it indicates check ring and packing consistency
- Note the date and who approved the process
Keeping sheets useful
A process sheet is only as good as its upkeep. Link it to the mold and the part revision, review it after any mold repair, and treat changes as controlled, not casual. For regulated customers, the process window and its validation evidence belong with the sheet. Print the Actual column on the first part approval so drift from the baseline is visible.
Common mistakes
Recording settings from a good day without noting the material lot, saving values in only one unit, leaving out drying details for hygroscopic resins, and not updating the sheet after process improvements. Another is recording setpoints but not the actual readings, which hides heater faults and sensor drift.
Frequently Asked Questions
What is a process sheet in injection molding?
It is a controlled record of the machine settings, material and conditions used to make approved parts with a specific mold. It lets another technician or shift reproduce the same process without guesswork.
Which settings are most important to record?
Material and drying, melt and mold temperature, pressures, hold time, cooling time, shot size with cushion, and the cycle time. Add speed profile and transfer position if your process relies on them.
How often should the sheet be updated?
Update it whenever an approved setting changes, after a mold repair or a resin change, and at scheduled reviews. Keep old revisions for traceability.
Can I use it for customer audits?
It can form part of your documented process control, but add your own document control fields and any customer required items. This template is a starting point rather than a certified form.
Netray can attach process parameter sheets to molds and routings in your ERP or MES, so setup data travels with the job instead of living in binders.
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