- Keep wall thickness steady within ±0.2 mm. The thick sections need to be hollowed out to prevent material buildup.
- Add symmetrical support ribs and rounded corners (R0.8‑1.5) to cut stress buildup.
- Use a draft angle over 1°‑2° to ensure the part won’t get pulled and bent during ejection.
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How to Deal with Warped ABS Injection‑Molded Parts
Warping, bending, and uneven shrinkage on ABS pieces mostly come from unbalanced shrinkage, internal stress, or uneven ejection force. You can settle the issue through part design, mold setup, injection settings, and post‑treatment.
1. Optimize your part design to stop warping early
2. Adjust your mold structure
- Arrange cooling channels evenly and keep mold‑temperature difference under ±2 ℃.
- Go for multi‑point symmetrical gates to balance plastic flow.
- Spread out ejector pins evenly and use large ejector blocks to avoid forced pushing.
3. Tweak injection‑molding machine settings
- Set the mold temperature to 50‑80 ℃ and the barrel heat to 180‑230 ℃.
- Use slow‑fast‑slow staged injection speed and moderate holding pressure.
- Give parts enough cooling time before ejection, and lower injection pressure when possible to reduce internal stress.
4. Post‑processing fixes
- Anneal finished parts 10‑20 ℃ under their heat‑distortion temperature and let them cool slowly to release stress.
- Clamp hot‑off‑mold pieces with fixtures while they cool to stop bending from their own weight.
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