I’m talking about the placement of the wires for the thermocouple and heater bands. These wires supply power and temperature control for the nozzle body and tip. If the heater band is constantly on or off, it is not controlling the temperature. This is poor temperature control and will not provide a consistent melt stream or process. So how do we get a melt stream uniform in temperature? The screw, barrel, and zone-temperature controllers must perform properly to get melt uniformity. This is a complicated balancing act, which involves screw design, resin, temperature settings, barrel wall design, coefficient of friction of pellet on barrel wall, and, well, the omnipresent Murphy’s Law. Melt consistency is further complicated in injection molding because the screw does not rotate continuously, it is reciprocating. Also, don’t forget that we typically cannot measure actual melt temperature as we are molding. I am not sure I understand all of these interactions, but I do have some tips on what causes zone-temperature override and what to do to gain control.