NORYL™ RESIN

INJECTION MOLDING GUIDE

SABIC
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And with more than 80 years of leadership.
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2
CONTENTS
1.0 ABOUT NORYL™ RESINS 4
The NORYL Family of Resins 5

2.0 INJECTION MOLDING

RECOMMENDATIONS 6
Material Handling and Drying 7
Machine Preparation, Mold Release Agents,
Barrel Selection and Screw Design 8
Molding Conditions, Melt Temperature 9
Screw Speed and Diameter, Back Pressure,
Shot Size and Injection Speed 10
Injection and Holding Pressure, Cushion,
Clamping Force, Regrind, Down Time, Purging 11

3.0 OVERVIEW OF
BASIC SETTINGS 13
Flowpath-wall section ratio 14
Recording Parameters, Changes and Trends 15

4.0 INJECTION MOLDING

TROUBLESHOOTING GUIDE 17
Common Issues, Causes, Remedies 18

CONTACT US 20

3
1.0

4
ABOUT
NORYL™ RESINS

The NORYL™ resin family is built on SABIC’s Semi-crystalline members of the NORYL family
proprietary polyphenylene ether (PPE) technology. include:
NORYL resins for injection molding exhibit a broad • NORYL GTX resin, which is compounded
range of outstanding properties for applications in with polyamide
water management, automotive, electrical, solar, • NORYL PPX resin, which is compounded
energy storage, building & construction, appliances with polypropylene
and many other industries.
NORYL GTX and NORYL PPX resins leverage the
The intention of this guide is to provide general flow and chemical resistance characteristics of
information and recommendations for molders and semi-crystalline materials, while adding the good
designer to consider when injection molding using dimensional stability, low moisture absorption
NORYL resins. and low creep tendency of the amorphous PPE
technology.
NORYL resin, which is compounded with high
impact polystyrene (HIPS), exhibits amorphous Whenever a recommendation is specifically
characteristics. important to either the amorphous or semi-
crystalline nature of the resin, it is referred to.
General recommendations are valid for the entire
NORYL resin product family.

PPE HIPS NORYL™

Fillers and Additives Enhance Performance
• Glass
PA NORYL GTX ™
• Impact Modifier
• Flame Retardant
(non-brominated, non-chlorinated) PP NORYL PPX ™
• Antioxidants
• Stabilizers
• Release ELASTOMER FLEX NORYL™

5
2.0

6
NORYL™ RESINS
INJECTION MOLDING
RECOMMENDATIONS

Material Handling and Preparation - Drying Special care must be taken when drying NORYL GTX ™
resin. If the material is too wet ( >0.05%) or too dry (
All NORYL™ resins require thorough drying prior to <0.02%), it will cause splay.
injection molding to assure maximum properties
in the molded part. Always check the datasheet It is highly recommended to closely monitor the
to determine the exact recommended drying moisture content during production and to carefully
temperature and drying time. size the dryer to the job, based upon the kg/h usage
and drying time needed.
DRYING DRYING
TEMPERATURE TIME MOISTURE The recommended drying temperature for all NORYL
MATERIAL [°C] [HRS] CONTENT GTX grades is 110°C. During a production standstill,
the dryer temperature should be dropped to
NORYL 100 – 120 2–4 < 0.02%
between 70°C to 80°C.
0.02%
NORYL GTX 100 – 120 2–3
- 0.05% The temperature of the cooling ring around the
NORYL PPX 65 – 75 2–4 < 0.02% hopper zone should be between 40°C and 60°C when
processing NORYL GTX. To avoid condensation at the
intake of the machine, in some cases it is better to
• A machine-mounted, dehumidifying hopper dryer work without cooling.
equipped with a closed-loop circulating air system
is preferred. When bulk drying, ensure the resin
remains dry via positive flow of dry air through the Signs of poor drying
conveying system.
• The hopper dryer should be equipped with a • Swelling purge
diffuser cone to ensure proper distribution of air • Drooling nozzle
flow and to allow “plug flow” of material through • Increased or variable flow rate
the hopper. • Voids in thin part areas
•  Batch drying can be accomplished with air • Splay on flow fronts of part
circulating, desiccant tray dryers with trays filled • Splay on filled parts
to a depth of no more than 25mm. Material dried in • Brittle parts
this manner should be placed in a sealed hopper
and residence time should be kept to a minimum.

7
Machine Preparation Depending on screw diameter, a compression ratio
of about 2:1 to 2.5:1 with a length to diameter ratio
Prior to introducing NORYL resins, the molding of 20:1 is preferred. A short feed zone (6 flights) and
machine barrel should be thoroughly cleaned either a long compression zone (11 flights) with a gradual
by purging or mechanically cleaning the cylinder with constant taper leading to a short metering zone
brass wool. (4 flights) are also suggested. The compression
should be accomplished over a gradual and constant
If the screw is removed, clean it and check carefully taper since sharp transitions can result in excessive
for nicks, cracks, or excessive wear. The check ring shear and material degradation.
should also be inspected for any abnormalities.
When specific screw selection is not possible, general
To check for cleanliness without removing the purpose screws with length to diameter ratios from
screw, purge with an unfilled, amorphous resin such 16:1 through 24:1 and compression from 1.5:1 to 3:1
as polystyrene and look for foreign particles or have been used successfully.  
discoloration in the air shot.
Vented barrels are not suggested for processing
Any evidence of contamination in the first several NORYL resins.
molded parts may indicate that the cleaning
procedure should be repeated. The non-return valve should be of the sliding
check ring type (See Figure below). Flow-through
clearances of at least 80% of the cross-section of
Mold Release Agents the flow area in the metering zone of the screw are
necessary. The check ring travel should be at least
The application of external mold release agents 4.5mm for small diameter screws (60mm diameter
to tool surfaces should be kept to a minimum. or less). Larger screws may require longer travel to
Initially, part sticking can be corrected by making provide the necessary flow-through area.
adjustments to pressure, temperature or cycle time.
In addition, draft angles, mold surface finish, and the
ejector pin area may require attention.
Intermittent part sticking can often be overcome by
Flow thru clearance
moderate application of a mold release spray. Since min. 3 mm Ring
some mold release sprays may have a detrimental Min. 4.5 mm
effect on the properties and surface appearance travel
of NORYL resins, compatibility testing is necessary
prior to their use. In some cases, formulation
adjustments are possible, permitting internal release
agents to be added to the resin during compounding.
Internal releases will reduce the tendency for part
sticking.
Body
Seat
Barrel Selection and Screw Design
Considerations

Conventional materials of construction for Ball check type screw tips are not suggested because
compatible screws and barrels are acceptable for they can cause degradation of the resin due to
processing NORYL resins. The use of bimetallic excessive shear and dead spots.
barrels is suggested for better abrasion and
corrosion resistance.

Metering Compression Feed

4 flights 5 flights 6 flights

Compression ratio 2-3:1

8
Molding Conditions Mold Temperature

As a general guideline, the standard grades of The usual range for processing unreinforced NORYL
NORYL resins are molded at different temperatures grades is from 65 to 100°C. Operating molds in this
– the lower temperatures for the low viscosity resins temperature range can also be used to maximize
and the highest temperatures for the high viscosity flow, improve knitline strength and optimize surface
grades. Increasing melt temperatures reduces finish.
viscosity and increases resin flow, thus providing
for longer flow for thin-wall sections and producing NORYL GTX resin should always be molded in
lower residual stress.  temperature-controlled molds. Optimal tool
temperatures for NORYL GTX resins are between
Mold temperatures are important in determining 120°C and 140°C, with a recommended mold surface
final part finish and molded-in stress levels. Cold temperature of 120°C.
molds are more difficult to fill, necessitating high
injection pressure and melt temperature and are not Full advantage of the rapid crystallization of NORYL
recommended when processing NORYL resins.   GTX resin can be realized by the effective location
of uniform cooling channels in the mold inserts and
Heated molds generally produce a part with better cores to achieve an even tool surface temperature.
finish and lower molded in-stress.
The fastest fill speed possible provides longer flow, For semi-crystalline materials such as NORYL GTX ™
fills thinner wall sections and helps to create a better and NORYL PPX ™ resins, high mold temperatures will
surface finish. Slower fill is suggested for sprue- produce higher degrees of in-mold crystallization.
gated and edge-gated parts to prevent gate blush, This, in turn, will result in high shrinkage values. Mold
splay and jetting. In thick wall parts (>4mm), slow fill temperatures that are too low, on the other hand,
helps reduce sinks and voids. For Typical processing may result in crystallization after molding, with the
parameters, see tables on page 14. risk of warpage during secondary operations.

Melt Temperature

Suggested melt temperatures for NORYL™ resin are

listed on page 14. Like the majority of thermoplastic
molding materials, NORYL resins are sensitive to
prolonged exposure to heat. Long residence times
and excessive melt temperatures should be avoided.
It is not recommended to exceed 8 minutes residence
time.

A relatively small increase in screw speed (RPM) can

result in a dramatic increase in melt temperature with
no change in controller set point. It is suggested that
melt temperatures be measured using hand-held
pyrometers. These measurements should be taken
on the thermoplastic melts after the machine is on
cycle.
 
When processing near, or at, the upper limit of the
melt range, the shot weight should approach 70%
to 80% of the cylinder capacity of the machine. If the
cylinder temperature exceeds the upper limit of the
suggested melt range, thermal degradation of the
resin and loss of physical properties may result. 

NORYL resin, like other engineered thermoplastics,

should not be left at elevated temperatures for
prolonged periods of time without occasional
purging.

9
Screw Circumferential Speed
and Screw Diameter 140
120 Maximum
Screw circumferential speeds (RPM) should be Optimum
100
adjusted to permit screw rotation during the Minimum

RPM
entire cooling cycle without delaying the overall 80
cycle (Figure right) but must not result in a screw 60
surface speed of more than 0.5m/s. Low screw 40
circumferential speeds will reduce glass fiber
20
damage during plastification when molding
reinforced grades.
0 20 40 60 80 100 120 140

Material degradation can occur at too high screw Screw Diameter [mm]
speeds due to excessive shear heating.
Graph 1: screw circumferential speeds suggestion
for NORYL resins

SCREW DIAMETER [MM]

RPM 18 25 30 35 40 45 50 60 70 80 90 100 110 120

20 0.02 0.03 0.03 0.04 0.04 0.05 0.05 0.06 0.07 0.08 0.09 0.10 0.12 0.13
40 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.13 0.15 0.17 0.19 0.21 0.23 0.25
60 0.06 0.08 0.09 0.11 0.13 0.14 0.16 0.19 0.22 0.25 0.28 0.31 0.35 0.38
80 0.08 0.10 0.13 0.15 0.17 0.19 0.21 0.25 0.29 0.34 0.38 0.42 0.46 0.50
100 0.09 0.13 0.16 0.18 0.21 0.24 0.26 0.31 0.37 0.42 0.47 0.52 0.58 0.63
120 0.11 0.16 0.19 0.22 0.25 0.28 0.31 0.38 0.44 0.50 0.57 0.63 0.69 0.75
140 0.13 0.18 0.22 0.26 0.29 0.33 0.37 0.44 0.51 0.59 0.66 0.73 0.81 0.88

Table 1: Calculating the screw circumferential speed [m/s] based on RPM and screw diameter

Back Pressure The fastest fill speed possible provides longer flow,
fills thinner wall sections and creates a better surface
A back pressure of 0.3 to 0.7 MPa is suggested finish. In thick parts, slow fill helps to reduce voids.
to insure a homogeneous melt and to maintain Thin-wall sections below 1.5mm always require fast
consistent shot size. injection speeds in order to fill the cavity and produce
high knitline strength. The fill rate of thick sections
Higher back pressure used to improve melt mixing may be reduced to aid packing when filling through
results in higher melt temperatures. When molding restricted gates.
reinforced grades, low back pressure will reduce  
glass fiber damage during plastification. Programmed injection is suggested for parts with
small gates (pin gates and subgates). A slow injection
rate can be used at the start to reduce shear, jetting
Shot Size and burning of the material.
 
The shot size should dictate the size of the machine Following maximum shear rates for NORYL resins
used. It is suggested that the optimum shot be 40% are recommendations and based on experience and
to 60% of the machine’s capacity. However, shots observations from different applications:
which are 20% to 75% of machine capacity have
been successfully molded when temperatures were MAXIMUM RECOMMENDED
precisely maintained and all processing conditions MATERIAL SHEAR RATE
were very closely controlled.
NORYL 40.000/s
NORYL FExxxxPW series 20.000/s
Injection Speed NORYL GTX 40.000/s
NORYL PPX 40.000/s
When selecting injection speed, careful consideration
must be given to adequate mold venting, resin melt Table 2: Maximum Recommended Shear Rate
temperature and injection pressure along with the
potential for jetting.  In practice, higher shear rates have been observed
without influence on mechanical or flame retardance
performance.
10
Injection Pressure use of regrind be possible, always use a set ratio of
regrind and virgin material.
The actual injection pressure will depend on variables
such as melt temperatures, mold temperature, part A maximum of 20% regrind should not be exceeded if
geometry, wall thickness, flow length and other mold retaining physical properties is important.
equipment considerations. Generally, the lowest
pressures which provide the desired properties, Grinder screen sizes should be 8 to 9.5 mm. If
appearance and molding cycle are preferred. a smaller size is used, too many fines could be
generated, creating molding problems such as
streaking and burning.
Holding Pressure
It is important to keep the ground parts clean and
Holding pressures from 60% to 80% of the injection to avoid contamination from other materials. Drying
pressure are adequate for normal requirements. time should be increased since regrind will not be
same size as virgin pellets and therefore moisture
For NORYL resin, it is suggested to apply a diffusion will be different. Regrind utilization may
decreasing holding pressure profile so as not to have an effect on color.
overpack the part and create in-molded stress.
Actual regrind usage should be determined for each
Holding pressure should be applied after the part is individual application, especially in cases when the
volumetrically filled. application needs to meet strict regulatory or testing
standards such as potable water certification or UL
Cushion testing.

The use of a small cushion reduces material

residence time in the barrel and allows for machine Down Time
variations. In general, the cushion should be big
enough to effectively apply holding pressure. When it becomes necessary to stop molding, the
following steps are suggested:
• Maintain cylinder temperature for interruptions up
Clamping Force to 15 minutes
• Decrease cylinder temperature by 50°C for periods
Once the total projected area of the complete shot from 15 minutes to 2 hours
(all cavity and runner areas are subjected to injection • Reduce further to 180°C for interruptions from 2 to
pressure) has been determined, 0.5 to 1.5 tons of 12 hours
clamping force should be provided for each cm² to • Purge out the barrel and shut off the heat for
avoid flashing of the part. Glass-reinforced resins periods longer than 12 hours
may require slightly higher clamping force (estimate
one ton per cm² of additional clamping force).
Purging
Wall thickness, flow length and molding conditions
will determine the actual tonnage required. Polystyrene and reground cast acrylic are effective
To determine an initial injection molding setting, it purging materials for NORYL™ resin. Purging should
is recommended to set up a higher clamping force be done within the melt temperature range for the
rather than too low a clamping force in order to particular grade of resin. It is important to have
prevent tool damage. proper ventilation during the purging procedures.

NORYL GTX ™ resin can be purged using the usual

Regrind procedures for standard nylon.

The reinforcing effect of glass or carbon fibers NORYL PPX ™ resin can be purged using the standard
decreases with repeated processing because of fiber procedures for polypropylene.
breakdown. Also, thermal degradation will cause
a decrease in mechanical properties, particularly
impact strength. Where molded components need to
meet specific demands for tensile or impact strength,
the use of regrind is not recommended until
thorough testing is conducted. Fiber breakdown and
thermal degradation can also effect the dimensions
of molded parts. Care should be taken with the
addition of regrind for use in applications where tight
dimensional tolerances must be met. Should the

11
3.0

12
OVERVIEW OF
BASIC SETTINGS
Screw
drive
motor

Mold

MELT MOLD NOZZLE ZONE 3 ZONE 2 ZONE 1 HOPPER

DRYING MOISTURE
ALL VALUES MENTIONED: TEMPERATURE (°C) CONDITIONS CONTENT
2-4 hours at
NORYL 280 - 300 100 – 120 280 – 300 280 - 300 270 - 290 250 - 270 60 - 80 0.02%
100-120°C
2-3 hours at
NORYL GTX 280 - 300 80 – 100 270 – 290 280 – 300 270 – 290 260 – 280 60 – 80 0.02%
100-110°C
2-4 hours at
NORYL PPX 260 – 300 40 – 65 260 – 300 255 – 290 250 – 290 245 – 290 60 - 80 0.02%
65 – 75°C
NORYL 2-4 hours at
290 – 320 80 – 120 290 – 320 300 - 310 280 – 300 270 – 280 60 - 80 0.02%
FExxxxPW 100-120°C

Table 3: General parameters for injection molding NORYL™ resin

For NORYL FExxxxPW series, a medium to low PARAMETER ADVISED SETTING

injection speed and tool temperature in combination
Screw length 20 – 26D
with a high melt temperature has been observed as
an optimal injection setting. Compression ratio 2:1 – 2.5:1

Screw speed 0.1 - 0.3 m/s

Please contact your SABIC representative for further
information on injection molding recommendations. Back pressure 30 – 70 bar

Injection speed Medium to Fast

Cushion 4 – 10 mm

Injection pressure As low as possible

Hold pressure 60 – 80% of Injection Pressure

Table 4: Recommended settings for molding NORYL™ resin

13
 Flowpath-wall section ratio
of selected NORYL™ resins

Below are charts showing the anticipated flow length

for various grades of NORYL resins, based on melt
and mold temperatures and gate pressure settings.

Flow Length Curves: NORYL™ NH6020 Resin Flow Length Curves: NORYL™ V0150B Resin

700 350
1mm 1mm
Flow Length [mm]

Flow Length [mm]

600 2mm 300 2mm
3mm 3mm
500 250
400 200
300 150
200 100
100 50
0 0
20 40 60 80 100 120 20 40 60 80 100 120
Gate pressure [MPa] Gate pressure [MPa]

Graph 2a: Flow length curves NORYL™ NH6020 resin Graph 2b: Flow length curves NORYL™ V0150B resin
T(melt) = 310°C, T(mold) = 115°C T(melt) = 300°C, T(mold) = 85°C

Flow Length Curves: NORYL™ FE1630PW Resin Flow Length Curves: NORYL GTX ™ 985 Resin

500 900
1mm 1mm
450 800
Flow Length [mm]
Flow Length [mm]

2mm 2mm
400 700
3mm 3mm
350 600
300
500
250
400
200
150 300
100 200
50 100
0 0
20 40 60 80 100 120 20 40 60 80 100 120
Gate pressure [MPa] Gate pressure [MPa]

Graph 2c: Flow length curves NORYL™ FE1630PW resin Graph 2d: Flow length curves NORYL GTX ™ 985 resin
T(melt) = 290°C, T(mold) = 100°C T(melt) = 310°C, T(mold) = 110°C

14
Record Injection Molding Parameters Periodic Changes

Continuous recording of injection molding Sources for periodic changes can be a result of the
parameters is always suggested and can help to temperature changes into the hot runner system (if
determine root causes of quality issues. the frequency is within several minutes) or can be
found within the material feeding (if the frequency is
When encountering quality issues during injection within several hours).
molding it is recommended to carefully evaluate
the type of issue and then create a detailed issue If the frequency is even longer (i.e. days) it can be a
resolution plan. It is important to not change more sign for changes of the ambient temperature.
than one injection molding parameter a time,
otherwise it will not be possible to isolate the effect
on the process. Change of Trend

Usually there are two types of failures: Root causes of volatile changes can easily be
• Periodical monitored and many times are an interplay of
• Change of trend changing material properties in terms of drying,
change from Lot A to B, masterbatch change,
different ratio of regrind, etc.

A change of trend is usually caused by machine or

tool defects. If the heating band of the injection
molding machine or a tool temperature controller is
Normal Fluctuation not working appropriately, this usually triggers the
change of trend.

Volatile Change

Change of Trend

Regular Oscillation

15
4.0

16
INJECTION MOLDING
TROUBLESHOOTING
GUIDE

17
ISSUE CAUSE REMEDY

Brittleness Wet material • Review drying procedure

Overheating • Reduce barrel/nozzle temperature
Molded-in stresses • Increase barrel/nozzle temperature
Poor part design • Eliminate sharp corners
Weld-lines • Increase injection pressure
• Increase melt temperature

Warped Parts Part temperature differential • Check mold cooling system

Excessive shrinkage • Increase part packing
Orientation of material • Change gate location
Poor part design • Add ribs or part thickness to improve stiffness
Ejection problem • Check for uniform wall thickness
• Increase cooling time
• Reduce mold temperature
• Increase ejector pin area

Flashing Inadequate clamp tonnage • Use a larger machine

High injection pressure • Reduce injection pressure
Misaligned platen • Align platen
Excessive vent depth • Review mold venting

Burn Marks Air trapped in cavity • Improve mold venting

Barrel or nozzle overheating • Check heater controls
Shear heat • Reduce injection speed
Contamination • Purge barrel
Hang-up in molding machine • Clean hopper dryer
• Remove and clean screw

Weak Weld-Lines Insufficient venting • Improve cavity venting

Injection speed or mold • Increase injection rate and tool temperature
temperature too low • Relocate gate or add overflow tab
Incorrect gate location

Surface Injection speed too low • Increase injection speed

Imperfections Cold melt/cold mold • Increase barrel temperature/mold temperature
(frosty surface or Wet material • Review drying procedures
white marks)

Sinks or Voids Holding pressure or time too low • Increase hold pressure or time
Insufficient feed • Increase shot size
Gate freezing off or located • Check gate dimension and location
improperly

Gate Blush Cold material • Add cold slug well in runner

Melt fracture • Increase melt temperature
• Reduce injection speed
• Increase gate size
• Add radius to gate

Dimensional Shot to Shot variation • Maintain adequate cushion

Inconsistency Melt temperature variation • Check for worn check ring
Inadequate packing • Check heater bands/controllers
• Increase hold time
• Enlarge gate to prevent premature freeze-off

Sticking Mold Over packing • Reduce injection pressure

Mold design • Reduce injection speed
• Check for undercuts
• Inspect ejector system
• Increase draft in tool

18
CONTACT US
Middle East and Africa
SABIC Global Headquarters
PO Box 5101
Riyadh 11422
Saudi Arabia
T +966 (0) 1 225 8000
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E info@[Link]

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Houston, Texas 77042
USA
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E productinquiries@[Link]

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The Netherlands
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Technical Answer Center

T (0) 0 800 1 238 5060
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E webinquiries@[Link]

Asia Pacific
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China
T +86 21 2037 8188
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