Case studies

Injection Molding Troubleshooting Case Studies

Five problems from Bob Gray's own programs: what was going wrong, how the root cause was found, and what fixed it.

Plumbing (PEX connectors)Recurring mold defect

A two-year underfill problem traced to one hidden part

Bob's role
Tooling Manager, family-owned injection molder in rural Iowa
Result
With the obstruction removed, all 8 cavities ran at full capacity. Two years of recurring tear-downs ended.
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Automotive (Tesla Model 3)Offshore sourcing

Recovering an offshore tool after unauthorized steel changes

Bob's role
Tooling lead for a Tier 1 automotive supplier
Result
The program passed PPAP and the OEM approved the parts while the permanent cavity was built.
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Automotive (Cadillac)Warpage

The flat part that took a week to solve

Bob's role
Engineer at an automotive OEM
Result
The part molded flat and scrap stopped.
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Automotive (Acura MDX)Flash, mold integrity

Why moving flash is not fixing flash

Bob's role
Tooling Program Manager for a Tier 1 automotive supplier
Decision
Bob refused to approve the change and held to the proper corrective action, even when the decision was escalated.
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Clear covers (instant tickets)Mold maintenance

Recurring marks on a clear part, solved at the source

Bob's role
Tooling Manager, family-owned injection molder in rural Iowa
Result
The recurring marks and daily re-polishing stopped.
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