The gloss transition defect of injection-molded surfaces should be mitigated because it creates a poor impression of product quality. Conventional approaches for the suppression of the gloss transition defect employ a trial-and-error approach and additional equipment. The causes of the generation of a low-gloss polymer surface and the surface change during the molding process have not been systematically analyzed. This article proposes the causes of the generation of a low-gloss polymer surface and the occurrence of gloss transition according to the molding condition. The changes in the polymer surface and gloss were analyzed using gloss and topography measurements. The shrinkage of the polymer surface generates a rough topography and low glossiness. Replication to the smooth mold surface compensates for the effect of surface shrinkage and increases the surface gloss. The surface stiffness and melt pressure influence the degree of mold surface replication. The flow front speed and mold temperature are the main factors influencing the surface gloss because they affect the development rate of the melt pressure and the recovery rate of the surface stiffness. Therefore, the mold design and process condition should be optimized to enhance the uniformity of the flow front speed and mold temperature.
Keywords: gloss transition defect; injection molding; mold surface replication; shrinkage; surface analysis; surface defect; surface gloss.