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The gas-assist process
differs from standard injection molding in some very distinct ways. The
gas-assist process does not require a cushion, whereas standard injection
molding needs a cushion in order to properly pack the part. The polymer
melt that is introduced into the mold controls the gas-assist process. The
gas takes the path of least resistance and displaces molten material and
compensates for volumetric shrinkage. The gas pressure takes the place of
the machine's pack and hold pressures, and packs the part throughout the
cooling stage. In standard injection molding, the part is only packed until
the gate freezes. Warp is reduced in the gas-assist part due to a more even
distribution of molding pressure through the thicker gas channels. The material
and gas channel geometry primarily determines the wall thickness of the
gas channel. It is almost impossible to influence the wall thickness with
the processing parameters. Once injection of the gas has commenced, it is
no longer possible to influence the filling process from outside the mold.
Basic techniques, shrinkage and warpage, residual wall thickness, weld line
prediction, and troubleshooting are covered in this section. At the end
of the cooling phase the gas is vented to atmosphere and a vent opening
remains in the part.