Materials Controls

Reliant Worldwide Plastics has a depth of knowledge and experience injection molding all thermoplastic-based resins. We utilize a multi-vendor strategy to ensure we have material required for your production in stock continuously. Here are just a few of the materials we commonly use during the molding process:

  • ABS
  • Nylon
  • Polycarbonate
  • Polyethylene
  • Polypropylene
  • Polyurethane
  • Glass Filled and Carbon Filled
  • Other Materials

Reliant has the capability of molding plastics utilizing pre-color or color concentrate mixed with a base resin with full traceability back to original manufacture. Reliant has two spectrometers in house to ensure all colors are within the specifications provided along with melt flow rheometer capability.

We can match any color variation required using sample chips or 31 point spectral data. We are able to program the spectrometers to read by either method and provide print-outs of a color comparison to the standard on any batch of material produced. These quality controls ensure that the color will be consistently maintained throughout your project.

Our melt flow rheometer can be programmed to determine either MVR (Melt Volume Rate) or MFI (Melt Flow Index) giving the customer the measure of how many grams of polymer pass through a standardized capillary under a standard load over time. Performing this in house testing on polymer lots or even during FAI’s (First Article Inspections) can reveal hidden differences between materials by subjecting them to flow and shear rates. This testing is especially useful when two “identical” materials with the same melt flow rate don’t behave the same during processing.
 

Manufacturing

At Reliant, we utilize statistical process control (SPC), an industry-standard methodology for measuring and controlling quality during the manufacturing process.  Quality data in the form of product or process measurements is obtained in real-time during manufacturing.  This data is then plotted on a graph with predetermined control limits. Control limits are determined by the capability of the process, whereas specification limits are determined by your product needs.

Data that falls within the control limits indicates that everything is operating as expected. Any variation within the control limits is likely due to a common cause—the natural variation that is expected as part of the process.  If data falls outside of the control limits, this indicates that an assignable cause is likely the source of the product variation, and something within the process should be changed to fix the issue before defects occur.

With real-time SPC we:

  • Dramatically reduce variability and scrap
  • Scientifically improve productivity
  • Reduce costs
  • Uncover hidden process personalities
  • Instantly react to process changes
  • Make real-time decisions on the shop floor

Benefits to our clients:

  • Provides surveillance and feedback for keeping processes in control signals when a problem with the process has occurred
  • Detects assignable causes of variation
  • Accomplishes process characterization
  • Reduces need for inspection
  • Monitors process quality
  • Provides a mechanism to make process changes and track the effects of those changes

Once a process is stable, meaning assignable causes of variation have been eliminated, we provide process capability analysis that compares to the product tolerance.