When a custom molder ran into problems with production of a decorative towel bar and end bracket, he contacted GE Polymerland for help.

The molder was using a clear acrylic in the end bracket and the parts were not surviving the load testing at final assembly. The acrylic parts were also experiencing a high rejection rate for sinks, voids and flow marks.

Roger Mansur, one of GE Polymerland's technical specialists was able to help the molder solve his problem through a "phone molding trial" to sample a different material.

"We had to make a lot of pre-arrangements and exchange information over the telephone prior to the actual phone molding trial," Mansur said. "Our up-front work paid off. The tooling and processing information I shared with the molder during and after the trial enabled him to use the original, cost-effective material in an application where it initially did not perform. The molder was also able to develop an alternative material for applications that would prove to be more demanding down the road."

According to Mansur, the top five things to remember when conducting a phone trial are:

1. Send several defective parts to a GE Polymerland technical specialist prior to the mold trial. The parts contain clues to what is potentially going wrong during the molding process. After close examination, the technical specialist can begin to derive problem-solving ideas. In the above case, several complete shots including sprues and runners were sent to the specialist along with additional parts displaying the various defects.

2. Set aside time for a phone conversation to develop a common vocabulary. This allows both parties to:

• develop a common vocabulary
• understand descriptions of the various problems
• identify locations of defects on the parts, and
• determine capabilities of the equipment involved

3. Select a desirable date and time to conduct the phone trial.

4. Prepare to have a reliable cell phone near the equipment so communications are clear and uninterrupted.

5. Prepare to have an adequate supply of materials available for the trial mold. This will make it easy to focus on describing results and making the suggested changes.

GE Polymerland's technical team is always available to provide you with the technical information you need to make sure your molding and extrusion processes are trouble free. For assistance, call 1-800-PLASTIC.

DISCLAIMER: THE MATERIALS AND PRODUCTS OF THE BUSINESSES MAKING UP THE GE PLASTICS UNIT OF GENERAL ELECTRIC COMPANY, ITS SUBSIDIARIES AND AFFILIATES ("GEP"), ARE SOLD SUBJECT TO GE POLYMERLAND'S STANDARD CONDITIONS OF SALE, WHICH ARE INCLUDED IN THE APPLICABLE DISTRIBUTOR OR OTHER SALES AGREEMENT, PRINTED ON THE BACK OF ORDER ACKNOWLEDGMENTS AND INVOICES, AND AVAILABLE UPON REQUEST. ALTHOUGH ANY INFORMATION, RECOMMENDATIONS, OR ADVICE CONTAINED HEREIN IS GIVEN IN GOOD FAITH, GE POLYMERLAND MAKES NO WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (I) THAT RESULTS DESCRIBED HEREIN WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (II) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN INCORPORATING GE POLYMERLAND MATERIALS, PRODUCTS, RECOMMENDATIONS OR ADVICE. EXCEPT AS PROVIDED IN GE POLYMERLAND'S STANDARD CONDITIONS OF SALE, GE POLYMERLAND AND ITS REPRESENTATIVES SHALL IN NO EVENT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS MATERIALS OR PRODUCTS DESCRIBED HEREIN. Each user bears full responsibility for making its own determination as to the suitability of GE Polymerland's materials, products, recommendations, or advice for its own particular use. Each user must identify and perform all tests and analyses necessary to assure that its finished parts incorporating GE Polymerland materials or products will be safe and suitable for use under end-use conditions. Nothing in this or any other document, nor any oral recommendation or advice, shall be deemed to alter, vary, supersede, or waive any provision of GE Polymerland's Standard Conditions of Sale or this Disclaimer, unless any such modification is specially agreed to in a writing signed by GE Polymerland. No statement contained herein concerning a possible or suggested use of any material, product or design is intended or should be construed, to grant any license under any patent or other intellectual property right of General Electric Company or any of its subsidiaries or affiliates covering such use or design, or as a recommendation for the use of such material, product or design in the infringement of any patent or other intellectual property right.

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