All,

One of the processing engineers at my company was sampling the part. After he sampled the part we had some issues with parts sticking so I went over to evaluate his process parameters.

The first thing I noticed is that he was transferring to pack/hold at roughly 30% of a full part (using velocity to fill 30% of the part and pack/hold to fill the rest). When I went over there to explain that we needed to adjust shot size and transfer position he got defensive and said there was nothing wrong with molding that way.

What are the negative consequences of not filling the part out 95%-99% of the way during first stage?