Injection molding is indispensable in the mass production of plastic parts, and the demands placed on high-performance applications continue to increase. As a result, quality control during production is gaining importance. The SKZ Plastics Center develops customized thermographic measurement systems tailored to individual customer requirements and integrates them seamlessly into existing processes. By combining expertise in measurement technology with knowledge of plastics processing, the organization provides comprehensive solutions for product quality assurance.
Within research and development projects, SKZ is designing measurement and testing systems based on thermography that use cost-effective thermal imaging cameras. These solutions enable automated, process-accompanying detection of deviations, even on complex components, while supporting complete control without the need for elaborate automation technology. The focus is on reliable inspection that can be implemented directly on the production line and extended to finished components when required.
Quality assurance aims to identify defects typical of injection molding at an early stage in order to stabilize output and performance characteristics. The range of defects addressed includes sink marks, pores, cavities, cracks and warping. Detecting such features during or immediately after molding helps prevent the downstream processing of nonconforming parts and contributes to consistent product quality.
Passive and active thermography
Thermography-based inspection can be implemented in two modes depending on the application. In passive thermography, the intrinsic heat of the freshly molded object is measured and analyzed using an infrared camera. In active thermography, the component is heated in a targeted manner, for example with flash lamps, to obtain insight into the interior of the test object. This approach extends the range of detectable irregularities beyond surface features to subsurface anomalies relevant to part integrity.
Process-integrated control
By deploying thermographic measurement systems in-line, manufacturers can implement automated error detection that accompanies the process and scales to complex geometries. The systems are designed for seamless integration into existing production environments and quality management workflows. In this way, thermography supports complete, efficient control of molded parts without relying on complex additional automation, aligning inspection intensity with the rising quality requirements in injection molding.
Non-destructive testing of injection-molded spoons using thermography. Both visible surface defects and hidden irregularities, some of which are characteristic of injection molding, are reliably detected. (Photo: SKZ)
