Injection molding trial record template showing actual process data, CTQ results and adjustment history — A trial record links actual molding conditions, sample results and engineering changes to a specific trial stage and tool revision.

T0–T2 Trial Documentation

Injection Molding Trial Record Template for T0–T2

An injection molding trial record should document what actually happened during a specific trial: the tool and revision used, machine and resin conditions, actual process data, cavity-identified samples, CTQ results and the changes made before the next engineering review.

Record Actual Conditions Capture the values and setup that produced the reviewed samples.

Link Samples to Evidence Maintain cavity, revision and trial-stage traceability for CTQ review.

Preserve Change History Record what changed, why it changed and the observed result.

View Required Trial Record Fields →

Scope: this template records trial evidence. It does not itself establish a validated process window, define production control limits or provide final mold acceptance.

Trial Record Purpose

What Is an Injection Molding Trial Record Used For?

A trial record creates a traceable link between the molding condition, the samples produced, the measured results and the engineering changes made during a specific T0–T2 trial.

Purpose

Preserve What Actually Happened

Record the actual machine, material, thermal and process condition associated with the samples reviewed during that trial.

Engineering Use

Connect Results to Changes

Link cavity-identified samples and CTQ results to the condition used, then preserve what changed and the observed result for comparison.

Update Trigger

Update When the Trial Condition Changes

Create or update the record when the trial stage, tool revision, machine, material or engineering condition changes in a way that affects evidence comparability.

Stage boundary: this record documents the evidence generated during a trial. Decisions about what T0, T1 or T2 evidence can approve belong to the T0 vs T1 vs T2 Mold Trial Approval Matrix .

Core Template Fields

What Fields Should an Injection Molding Trial Record Include?

The record should connect trial identity, actual molding conditions, cavity-specific results and engineering changes in one traceable document. Record actual values where available rather than relying only on nominal machine setpoints.

Field Group	What to Record	Why It Belongs in the Trial Record	Evidence Type
Project & Traceability	Project or part ID, mold ID, tool revision, trial stage, machine ID and cavity identification.	Links every reviewed sample and result to the correct tool, revision and trial event.	Traceability record
Material Preparation	Resin grade, lot, regrind ratio where applicable, drying temperature, drying time and available moisture result.	Shows the material condition associated with the samples being evaluated.	Material actuals
Mold & Machine Setup	Relevant clamp, ejector, hot-runner, mold-temperature and other setup conditions used for the trial.	Preserves the setup associated with the recorded molding result.	Setup record
Thermal & Filling	Actual melt and mold temperatures, injection stages, fill time and V/P transfer position or trigger.	Connects fill behavior and reviewed samples to the actual molding condition.	Process actuals
Hold, Cooling & Weight	Hold pressure and time, cooling time, cycle actual and cavity-specific part weight where relevant.	Provides comparable evidence when reviewing changes between trial conditions.	Condition result
CTQ Results	CTQ identifier, nominal or specification, actual result, cavity ID and review status where required.	Links the measured result directly to the sample and condition that produced it.	Measurement result
Adjustment History	Before condition, change made, reason, after condition, observed result and related issue reference where applicable.	Preserves the engineering sequence between one reviewed condition and the next.	Change history
Reviewed Operating Range	Target or reviewed limits only when they have been established by the applicable engineering study or approval process.	Allows the record to reference an established range without claiming that the trial record itself validated that range.	Referenced limit

Operating-range boundary: a trial record may document an operating range once one has been established, but the record itself does not validate that range. Experimental range development and capability evidence belong to Scientific Molding Process Window Validation .

CTQ measurement result linked to an injection molding trial record and actual molding condition — A measured CTQ result becomes more useful when it can be traced to the actual trial condition and cavity that produced the sample.

Actual Process Evidence

Why Record Actual Values Instead of Machine Setpoints Alone?

Machine setpoints describe the intended setup, but they do not always describe the actual condition associated with the reviewed sample. A useful trial record therefore captures measured or observed actual values where they are available and relevant.

Thermal Condition

Record actual melt or mold-temperature evidence where measured, rather than assuming controller settings fully represent the material and tool condition.

Filling & Transfer Condition

Record the fill time, V/P transfer behavior and relevant pressure or timing values used for the sample so later trials can be compared against the correct condition.

Sample & CTQ Result

Link cavity-specific weight, dimensional or other CTQ results to the actual recorded condition so engineering changes can be evaluated against comparable evidence.

Scope: recording actual values improves traceability, but the trial record does not by itself prove process capability, establish a validated process window or define universal stability limits.

Record Completion Logic

How Should an Injection Molding Trial Record Be Completed?

Complete the record in the same sequence that the evidence is generated. The goal is to preserve which condition produced which sample, what changed and what happened afterward, without overwriting earlier trial evidence.

Identify the Trial Condition

Start with the trial stage, mold and drawing revision, machine, cavity identification, resin lot and other information needed to identify the specific run.

Record Conditions and Results Together

Capture the relevant actual process values and link retained samples, part weight or CTQ results to the condition under which they were produced.

Preserve Before-and-After Changes

Do not overwrite the previous condition. Record the change, reason, updated condition and observed response so later comparisons retain their engineering context.

Record the Trial Disposition

Note whether the reviewed condition is retained, requires another trial or is linked to an open issue. Significant corrective actions can reference the Mold Trial Issue Tracking Sheet .

Update rule: create a new identifiable condition whenever a material, machine, tooling or process change affects the comparability of the trial evidence. Keep the previous entry visible rather than replacing it with the latest values.

Document Boundary

What Does This Trial Record Not Replace?

A trial record documents what happened during a specific molding trial. It supports traceability and later engineering review, but it does not replace the documents that define execution, dimensional evidence, validated limits or final release.

Trial Execution

Mold Trial Checklist

The record captures conditions and results; the Mold Trial Checklist defines what engineers should check during T0–T4 execution after the mold is mounted.

Dimensional Evidence

FAI or CTQ Inspection Report

CTQ results can be referenced in the trial record, but detailed ballooning, inspection methods, measured characteristics and formal dimensional disposition belong in the applicable FAI or inspection report.

Production Control

Validated Range & Process Control Sheet

The record may reference an established operating range. It does not experimentally validate that range or define the production control limits, reaction rules and revalidation triggers used on the shop floor.

Formal Release

Validation & Final Acceptance

A completed record can support downstream evidence review, but capability, PPAP or other required validation and final tool release follow the separate Injection Mold Validation Guide and project requirements.

Simple boundary: Trial Record = what was run and what happened. Checklist = what to check. FAI = detailed dimensional evidence. Validation and production-control documents = what has been formally demonstrated or released.

Preview of the injection molding trial record template for T0 to T2 trial data and CTQ results — One-page trial record layout for traceability, actual process data, CTQ results and adjustment history.

Downloadable Engineering Template

Download the Injection Molding Trial Record Template

Use this one-page PDF to organize the key information generated during a T0–T2 mold trial and keep the reviewed samples, process condition and engineering changes traceable to the same trial record.

Trial stage, mold revision and machine ID
Resin lot and preparation actuals
Thermal, filling, V/P, hold and cooling data
Cavity-specific weight and CTQ results
Before-and-after adjustment history
Reviewed operating limits, when already established

Download Trial Record Template PDF →

Template fields should be adapted to the mold, resin, customer requirements and evidence required for the specific trial.

Illustrative filled injection molding trial record showing process conditions, CTQ result and adjustment history — Example of a filled record linking one trial condition to its measured result, engineering adjustment and next-stage disposition.

Filled Record Example

Example of a Completed Injection Molding Trial Record

The example below shows how one trial entry can connect the tool revision, material, actual process condition, CTQ result and adjustment history without treating the recorded values as universal molding limits.

Illustrative T1 Record — PA66-GF30 Molded Part

Trial Stage

T1 Engineering Review

Mold Revision

Rev. B / Tool Update 02

Resin

PA66-GF30 / Lot recorded on trial sheet

Actual Melt Temperature

282°C — illustrative measured value

V/P Transfer

14.20 mm

Hold Condition

620 bar / 5.5 s

Sample Result

Cavity identified; part weight recorded

CTQ Result

Dimension A: 10.05 mm / Spec. 10.0 ±0.1 mm

Adjustment

V/P position adjusted; reduced observed flash

Disposition

Ready for T2 engineering review

Condition Traceability The sample can be traced to the mold revision, material and recorded molding condition.

Result Traceability The CTQ result remains connected to the sample and condition that produced it.

Change Traceability The record preserves what changed and the observed result before the next review.

Illustrative example only: temperatures, pressures, times, dimensions and other values shown here are sample data, not SPI-wide acceptance criteria or recommended process limits. Actual requirements depend on the part, resin, mold, machine and agreed project criteria.

Trial Record FAQ

Injection Molding Trial Record Template Questions

These questions clarify what belongs in a T0–T2 trial record and how the document differs from process validation, production control and formal dimensional inspection records.

What should an injection molding trial record include?

A useful trial record should identify the project, mold revision, trial stage, machine, resin lot and cavity, then connect those details to the actual molding condition, retained samples, CTQ results, adjustment history and trial disposition. The objective is traceability between what was run and what result was observed.

What is the difference between a trial record and a process control sheet?

A trial record documents the conditions and results from a specific development trial. A production process control sheet defines the approved limits, monitoring requirements, reaction rules and other controls used after the process has reached the applicable production-control stage. The two documents therefore serve different lifecycle purposes.

When should a T0–T2 trial record be updated?

Update the record whenever a new trial condition produces evidence that must remain distinguishable from the previous condition. This can include a change in trial stage, tool revision, machine, material or relevant process setting. Previous entries should remain identifiable rather than being overwritten by the latest values.

Does a trial record establish a validated process window?

No. The record can document conditions tested during development and may reference an operating range once one has been established, but recording upper and lower values does not itself validate a process window. Validation requires the separate engineering study, evidence and acceptance criteria defined for the project.

Is a mold trial record the same as an FAI report?

No. A trial record can include or reference selected CTQ results so they remain linked to the molding condition that produced the sample. An FAI or dimensional inspection report provides the more detailed characteristic-level measurement evidence, inspection method and formal dimensional disposition required by the project.

Trial Record Engineering Review

Need a Second Review of Your T0–T2 Trial Record?

Send your current trial record, drawing revision, CTQ information and relevant trial findings. SPI can review whether the record clearly links the trial condition, samples, measured results and engineering changes, and identify important traceability gaps before the next review.

What to Send

Current T0–T2 record, drawing revision, available CTQ results and any significant adjustment or open finding.

What We Review

Missing record fields, sample-to-condition traceability, unclear change history and evidence that may need better identification.

Request a Trial Record Review →

This engineering review supports documentation quality and traceability; it does not replace project-specific validation, customer approval or final mold acceptance.