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Defect Definitions

This document defines various defects that can occur in extruded sheet materials, providing descriptions and potential causes for each defect type. It includes 24 different defect definitions such as pinch marks, die drool, contamination, orange peel appearance, pinholes, and more. Each definition describes what the visual appearance of the defect is and sometimes lists the probable cause, such as a hang up in the die during extrusion or outgassing of moisture. The definitions are intended to help identify and classify different issues that can arise in extruded sheet production.

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zakkerenbanget
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
1K views

Defect Definitions

This document defines various defects that can occur in extruded sheet materials, providing descriptions and potential causes for each defect type. It includes 24 different defect definitions such as pinch marks, die drool, contamination, orange peel appearance, pinholes, and more. Each definition describes what the visual appearance of the defect is and sometimes lists the probable cause, such as a hang up in the die during extrusion or outgassing of moisture. The definitions are intended to help identify and classify different issues that can arise in extruded sheet production.

Uploaded by

zakkerenbanget
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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DEFECT

DEFINITIONS

PINCH MARKS

DIE LINE

An area of the extruded sheet that appears


to have bonded to itself. Generally this will
appear as a small bow-tie.

Straight sharp lines in either cap surface


or substrate the is visible in the finished
part, probable cause-material hang up in
die creating an interruption of the flow of
polymer during extrusion process.

GEL/BUMP

DIE DROOL

Spherically shaped defect, potentially visible


in both unformed and formed sheet, typically
non-contrasting and originates from an unmelted portion of the resin. Often identified
with a tail in the extrusion direction.

Degraded talc residue the builds up and


breaks off from die lip. Generally seen on
the backside of sheet. Varies in size
and shape.

CONTAMINATION

BREAKOFF - DEGRADING
MATERIAL

Incompatible material within the substrate


that manifests itself in the formed part as a
protrusion in A surface. Typically will see
a correlating depression in the backside of
the formed sheet.

Appears as a sharp line followed by a


deposit of material that typically looks like
a small ball or bump.

ORANGE PEEL APPEARANCE

BREAKOFF - COLOR

Typically seen in high gloss surfaces as


a wavy pattern of light and dark areas.
Depending on the slope of the material, the
light is reflected in various directions.

Swirling appearance of a contrasting color.

MOTTLING APPEARANCE

POCK MARK/DIMPLE

Similar to orange peel, but larger, more


cloud-like patches.

Circular depression generally seen on the


backside surface of the sheet. Depending
on sheet thickness/depth of draw minor
pock marks may not appear in the A
surface after forming.

PINHOLE

BLACK SPECK

Concave recess in A surface of sheetprobable cause-out gassing during forming


process due to moisture in the
cap resin.

Typically carbonized or chared material,


from either resin pellet or extruder, that is
generally seen in flat sheet surface.

PIT

PATTERN WASHOUT

Concave defect circular in shape and


generally void of material in the area or
poorly dispersed color concentrate. Size
varies and can be on both A and
B surfaces.

Embossed pattern appears very shallow


or undefined.

DEFECT
DEFINITIONS

PHANTOM LINES

GAUGE VARIATION

An interruption or restriction of resin flow


through the die. Obvious weld line on B
surface, typically visible after forming.

Thickness variation across the web width


of the extruded sheet. Variation exceeds
PMC Standard or specified tolerances
determined by the customer.

CAP OPACITY

GLOSS

Does not match Master Sheet (not opaque)


core color may show through, changing the
color appearance.

Gloss evaluation, typically in smooth


products, appears to be more or less
reflective than the target or expected
results. This is sometimes referred to as
more dull or more shiny.

Sheet too opaque > change color appearance

OFF COLOR

MOISTURE

Expected color either visually does not


match the target or the numeric readings
exceed the customers specified tolerance.

Where excessive moisture in the material


evaporates during the extrusion process
and leaves small visual depressions in the
surface of the product.

CORE/ANGEL HAIRS

OUT OF SPEC- LENGTH,


WIDTH

Thin pieces of plastic or masking from


the shear process that can be trapped
between sheets and cause an impression
or remain imbedded.

Dimension exceeds specified tolerances


determined by the customer.

CORE SHOWING

ROLL BOUNCE

Cap or laminate does not cover entire core,


leaving core exposed.

An area of the product where the stack


rolls were opened or the bead forced
the stack roll to open. This appears as
an semi-irregular line in the tranverse
direction of the sheet.

DELAMINATION

WARPED MATERIAL

When two components in a product will not


adhere completely to each other.

Sheet material that bows or lifts from a flat


surface beyond the acceptable tolerance.

FLOW LINES
An interruption or restriction of resin
flow through the die. Less severe than
a Phantom line, cant feel, and typically
visible after forming.

DEFECT REFERENCE CARD

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