Journal articles: 'Multi component injection molding'

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Yang, Lung Jieh, Chung Yu Kao, and Chin Kwang Huang. "Development of Flapping Ornithopters by Precision Injection Molding." Applied Mechanics and Materials 163 (April 2012): 125–32. http://dx.doi.org/10.4028/www.scientific.net/amm.163.125.

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The authors investigate the component fabrication of a flapping ornithopter with 21.6 cm wing span by using precision injection molding. For making a bio-mimicking flapper like birds, two fold of plastic injection moldings have been done. Firstly the flapping mechanism of a 4-bar linkage gear transmission module has been studied, and the according plastic components for the gear transmission module were designed as light as possible. Thereafter the injection flow analysis in the multi-mold cavity and the fabrication parameters of the molding process has been implemented. The finished polyoxymethylene (POM) components for the transmission module of 1.2 gram in mass finally verify the design and process of the precision injection molding. After the ornithopterGolden Snitchwas assembled and tested with the fore-mentioned plastic 4-bar linkage, a maximum flight record of 480 sec was created in 2010. The second framework of injection molding is to design a bird-like expandable polystyrene (EPS) fuselage with 19.5 cm in length as the mechanical protection. After this ornithopterGolden Snitch-Prowas assembled, it has a successful flight of 230 sec and 100 times of landing capability. In summary, the fabrication of a polymeric bird-like flapper is proved, and the precision injection molding technique shows its feasibility in realization of ornithopters.

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Timmel, Tristan, Alexander Hackert, Tomasz Osiecki, Colin Gerstenberger, and Lothar Kroll. "Combined Injection Molding Technology for Dynamically Stressed Multi-Material Coupling Elements." Key Engineering Materials 744 (July 2017): 322–26. http://dx.doi.org/10.4028/www.scientific.net/kem.744.322.

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The manufacturing of high load components in automotive and mechanical engineering demands for an increased usage of combined plastics processing procedures. In practice, full plastic hybrid components are produced in a series of individual processes such as thermoforming or injection molding. The constructive implementation has often only material-substituting character wherein the high potential for lightweight anisotropic fiber composites is exploited only to a limited extent. Based on the application of a coupling brace in a vehicle, a new component design for function-integrated interface elements is enabled by an integrated injection molding technology. The targeted transfer of high local stresses by load-bearing insert elements regarding contoured metal sheets or Fiber Reinforced Thermoplastic Composites (TP-FRC) semi-finished products with endless fiber reinforcement enables efficient dimensioning of components. This fusion of technologies to a Multi Material Design (MMD) form the basis for novel weight-optimized, as well as cost-effective applications and lead to a high bending stiffness and high strength of structures. The composite strength of MMD components is increased by a variation and optimization of the thermoplastic/TP-FRC respectively thermoplastic/metal-interfaces. This objective will be achieved by highly efficient and integrated process flows and by the new entire construction of the component.

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Chen, Jin Nan, Qian Chao Mao, and Jian Wang. "Study on Injection Molding of Single Polymer Composites." Advanced Materials Research 1052 (October 2014): 482–88. http://dx.doi.org/10.4028/www.scientific.net/amr.1052.482.

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This article gives an overview of study on injection molding process of thermoplastic polymer SPCs. The thermoplastic polymer Polypropylene (PP) was selected as the experimental materials. Our study proves that advantages of the PP SPCs are friendly recyclability and excellent fire/matrix adhesion. PP SPCs samples had good interfacial compatibility and bonding properties. The one-component SPCs have better interfacial bonding than the multi-component SPCs. Injection molding is the most effective method with a large process window and short cycle time for processing a thermoplastic SPC. Injection molding could be developed to realize PP SPCs production.

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Löhner, Martin, and Dietmar Drummer. "Influence of Processing Parameters in Reaction Injection Foam Molding for Multi-Layer Parts on Foam Structure and Mechanical Properties." Applied Mechanics and Materials 805 (November 2015): 131–38. http://dx.doi.org/10.4028/www.scientific.net/amm.805.131.

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Reaction injection molding is a plastic processing method to produce net shape parts using reactive systems. By integrating semi-finished products as inserts, complex multi-layer parts can be generated in highly integrative and energy efficient processes. The material by far mostly used is polyurethane, a polymer which results from the reaction of isocyanate and polyol. By adding blowing agents, like for example water, to the polyol component, foamed parts can be realized. In contrast to thermoplastic injection molding a chemical reaction takes part during molding within the cavity. Therefore the processing parameters have a significant effect on this chemical reaction and on the properties of the finished part.In this work the influences of different processing parameters like for example mold temperature and injection volume on the resulting foam structure are investigated for reaction injection foam molding. Therefore multi-layer parts based on polyurethane materials (thermoplastic and reactive) were molded varying relevant processing parameters. The foaming took place within an open cavity. The resulting foam structures were characterized using scanning electron microscopy (SEM). Additional the multi-layer parts were characterized mechanically to reveal the resulting effects on the mechanical properties of parts containing a foamed reactive polyurethane component.

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Loaldi, Dario, Francesco Regi, Federico Baruffi, Matteo Calaon, Danilo Quagliotti, Yang Zhang, and Guido Tosello. "Experimental Validation of Injection Molding Simulations of 3D Microparts and Microstructured Components Using Virtual Design of Experiments and Multi-Scale Modeling." Micromachines 11, no. 6 (June 24, 2020): 614. http://dx.doi.org/10.3390/mi11060614.

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The increasing demand for micro-injection molding process technology and the corresponding micro-molded products have materialized in the need for models and simulation capabilities for the establishment of a digital twin of the manufacturing process. The opportunities enabled by the correct process simulation include the possibility of forecasting the part quality and finding optimal process conditions for a given product. The present work displays further use of micro-injection molding process simulation for the prediction of feature dimensions and its optimization and microfeature replication behavior due to geometrical boundary effects. The current work focused on the micro-injection molding of three-dimensional microparts and of single components featuring microstructures. First, two virtual a studies were performed to predict the outer diameter of a micro-ring within an accuracy of 10 µm and the flash formation on a micro-component with mass a 0.1 mg. In the second part of the study, the influence of microstructure orientation on the filling time of a microcavity design section was investigated for a component featuring micro grooves with a 15 µm nominal height. Multiscale meshing was employed to model the replication of microfeatures in a range of 17–346 µm in a Fresnel lens product, allowing the prediction of the replication behavior of a microfeature at 91% accuracy. The simulations were performed using 3D modeling and generalized Navier–Stokes equations using a single multi-scale simulation approach. The current work shows the current potential and limitations in the use of micro-injection molding process simulations for the optimization of micro 3D-part and microstructured components.

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Xie, Zhi Peng, Lin Lin Wang, Xian Feng Yang, and Zhen Ting Zhang. "Water Debinding for Zirconia Powder Injection Molding." Key Engineering Materials 368-372 (February 2008): 732–35. http://dx.doi.org/10.4028/www.scientific.net/kem.368-372.732.

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Water debinding is an important debinding technique for ceramic injection molding. However cracks or blisters usually generate during water extraction. In this paper, two types of multi-component binder systems were studied: (1) a major fraction of polyethylene glycol (PEG), and a minor fraction of polyvinyl butyra (PVB) and other additives. (2) a major fraction of PEG, and a minor fraction of polymethyl methacrylate (PMMA) and other additives. Mechanism of defects generation was investigated, and PEGs with various molecular weights were introduced to avoid cracks or blisters during the process. Further more, the compatibilities of PEG/PVB and PEG/PMMA were studied. The results showed that PEG and PMMA exhibited better compatibility, with the feedstock more homogeneous and sintered ceramic parts higher strength.

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Lei, Chen Jian, Jun He Yu, Hong Fei Zhan, Lei Chen, and Zhong Ren Jiang. "Multi-Objective Optimization Design for Double Toggle Clamping Unit of Injection Molding Machine." Applied Mechanics and Materials 201-202 (October 2012): 15–19. http://dx.doi.org/10.4028/www.scientific.net/amm.201-202.15.

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Clamping unit is an important component of injection molding machine. The clamping force and the clamping speed of clamping unit not only effect on the quality of molding products, but also determine the cyclic number. The large force amplification and large stroke ratio can reduce energy consumption and improve the productive efficiency. In this article, force amplification ratio and stroke ratio were used as the optimization goals. Non-dominated sorting genetic algorithm was used as the optimization method. The optimization result was better than the original design. So this article provides a reference for the same or similar product’s optimization.

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Kuang, Wei Hua, and Ju Liang Liu. "Forming Process and Technology Research of Mobile Telephone Frame." Applied Mechanics and Materials 20-23 (January 2010): 1401–4. http://dx.doi.org/10.4028/www.scientific.net/amm.20-23.1401.

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Injection molding is widely used to produce a variety of parts, from the smallest component to entire body panels of cars. It has some advantages, including high production rates, repeatable high tolerances, ability to use a wide range of materials, low labour cost and minimal scrap loss. As a case, the paper introduced the application of MoldFlow software in injection molding development of the mobile telephone frame. Best gate location was obtained. The numerical simulation provided scientific and valuable injection process information. At last, a multi-cavity injection mold for mobile telephone frame was designed, and the NC machining of the mold core was programmed by UG NX software.

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Piotter, Volker, Klaus Plewa, Tobias Mueller, Andreas Ruh, Elvira Vorster, Hans Joachim Ritzhaupt-Kleissl, and Juergen Hausselt. "Manufacturing of High-Grade Micro Components by Powder Injection Molding." Key Engineering Materials 447-448 (September 2010): 351–55. http://dx.doi.org/10.4028/www.scientific.net/kem.447-448.351.

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Powder injection molding (MicroPIM) has a considerable potential for the production of high-value metal and ceramic micro components. This does not only apply to technical aspects but, due to the deployability of mass production, also to economic ones. The current status can be summed up by the following key data: latest trials revealed smallest struc-tural details in the 10µm range or lower. Theoretical densities of up to 99% were achieved depend-ing on the particular powder applied. Typical materials processed are metals (Fe, Cu, 316L, 17-4PH, W and W-alloys etc.) or ceramics (aluminum/zirconium oxide etc.). Best surface qualities were obtained with ultrafine or even nano-doped ceramic powders. Another major line of development is multi-component or assembly injection molding. These proc-esses do not only reduce assembly expenditure, but also allow for the use of new functional material combinations. Interesting examples are ceramic micro heating elements or gear wheel/shaft samples which can be performed as fixed or movable combinations. Micro inmold-labelling using PIM feed-stocks offers further promising opportunities.

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Oliveira, D., A. Mateus, P. Carreira, F. Simões, and C. Malça. "Water Assisted Injection Molding for Single and Multi-branched Tubular Components." Procedia Manufacturing 12 (2017): 141–49. http://dx.doi.org/10.1016/j.promfg.2017.08.018.

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Schlitt, C. U., M. Hartung, A. Rüppel, R. U. Giesen, and H. P. Heim. "UV Pre-Treatment for Polycarbonate for Bonding LSR in a Multi-Component Injection Molding Process." International Polymer Processing 34, no. 1 (March 7, 2019): 30–36. http://dx.doi.org/10.3139/217.3509.

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Li, Tao, Su Xia Zhang, Qing Fa Li, Siew Fei Pook, and Zi Yan Amanda Ong. "Strength Evaluation of Joint Formed by Powder Injection Molding." Key Engineering Materials 447-448 (September 2010): 412–16. http://dx.doi.org/10.4028/www.scientific.net/kem.447-448.412.

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Powder injection molding technology is currently applied to the joining processes to produce multi-functional components. In this paper, the strength of the joint of green and sintered samples produced by powder injection molding was evaluated using four-point bending test. The microstructures of the green samples showed that a very good joint was formed by the re-melting of the first injection molded half part followed by a high pressure compacting in the second injection molding. The strength of joined green samples was almost equal to the reference green samples without joining. The microstructures and flexure strength of sintered joined samples, which was more than 90% of base materials, showed that the good joining was maintained after sintering. This high strength sintered joint was an integrative result of powder injection molding and sintering diffusion. The crack observed at the sample surface accounted for the slight drop of the strength.

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Nishiyabu, Kazuaki, Yasuhiro Kanoko, and Shigeo Tanaka. "Innovations in Micro Metal Injection Molding Process by Lost Form Technology." Materials Science Forum 534-536 (January 2007): 369–72. http://dx.doi.org/10.4028/www.scientific.net/msf.534-536.369.

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The production method of micro sacrificial plastic mold insert metal injection molding, namely μ-SPiMIM process has been proposed to solve specific problems involving the miniaturization of MIM. The sacrificial plastic mold (SP-mold) with fine structures was prepared by injection-molding polymethylmethacrylate (PMMA) into Ni-electroform, which is a typical LIGA (Lithographie-Galvanoformung-Abformung) process. Stainless steel 316L feedstock was injectionmolded into the SP-mold which had micro structures with multi-pillars. The green compact was demolded as one component with the SP-mold, which was decomposed along with binder constituent of feedstock in debinding process. This study focused on the effects of metal particle size and processing conditions on the shrinkage, transcription and surface roughness of sintered parts, which were evaluated by SEM (Scanning Electron Microscope) observation.

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Nasir, S. M., Khairul Azwan Ismail, Z. Shayfull, and Norshah Afizi Shuaib. "Comparison between Single and Multi Gates for Minimization of Warpage Using Taguchi Method in Injection Molding Process for ABS Material." Key Engineering Materials 594-595 (December 2013): 842–51. http://dx.doi.org/10.4028/www.scientific.net/kem.594-595.842.

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In this study, a mold is designed in single and dual type of gate in order to investigate the deflection of warpage for thick component in injection molding process. Autodesk Moldflow Insight software was used as a medium for experimental tested. Nessei NEX 1000 injection molding machine and P20 mold material details were entered in this study to get more accurate data on top of Acrylonitrile Butadiene Styrene (ABS) as a molded thermoplastic material. Taguchi orthogonal array, analysis of Signal to Noise (S/N) ratio and Analysis of Variance (ANOVA) were implemented to get the best combination of parameter and significant factor that affect the warpage problem for both types of gates. Coolant inlet temperature, melt temperature, packing pressure and packing time are the selected parameter that used in this study. A conformation test is conducted to verify the combination parameters optimized. From the result, multi gates used was founded that can decrease the deflection of warpage for thick product. From ANOVA, the most significant factor is melt temperature for single gate, and coolant inlet temperature for multi gate. Packing pressure and packing time were slightly influence on warpage problem for both studies.

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Basir, Al, Abu Bakar Sulong, Nashrah Hani Jamadon, and Norhamidi Muhamad. "Bi-Material Micro-Part of Stainless Steel and Zirconia by Two-Component Micro-Powder Injection Molding: Rheological Properties and Solvent Debinding Behavior." Metals 10, no. 5 (May 2, 2020): 595. http://dx.doi.org/10.3390/met10050595.

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From the micro-powder injection molding (μPIM) process, a two-component micro-powder injection molding (2C-μPIM) process has evolved due to the growing demand for multi-functional micro-components in avant-garde applications. 2C-μPIM technology provides the opportunity to conjugate distinct materials within one part. Stainless steel (SS 17-4PH) and 3 mol.% yttria-stabilized zirconia (3YSZ) are characteristically recognized for their corrosion resistance and high hardness. In this work, the obtained critical powder volume concentration (CPVC) of SS 17-4PH and 3YSZ powders were 71.7 and 47.1 vol.%, respectively. Solid loadings of 2 and 3 vol.% less than the CPVC were considered as the optimal content for both powders. Feedstocks were obtained by mixing SS 17-4PH and 3YSZ powders with a binder system comprised of palm stearin (PS) and low-density polyethylene (LDPE). The rheological behaviors of the prepared feedstocks were assessed to figure out the feedstocks having the best rheological properties. The feedstocks of SS 17-4PH and 3YSZ with powder loadings of 69 and 44 vol.% were eventually injected to produce bi-material micro-parts. The optimal solvent debinding temperature of the green bi-material micro-part was then investigated, and it was found that 73.3% soluble binder was removed when bi-material was immersed in acetone at 70 °C for 40 min.

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Sun, Xiao Fang, Qian Hu, Meng Fei Zhou, and Hai Tian Pan. "Intelligent Modeling of Injection Molding Process Based on PLS-NN." Applied Mechanics and Materials 488-489 (January 2014): 988–94. http://dx.doi.org/10.4028/www.scientific.net/amm.488-489.988.

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Considering the problems of small sample, non-linear, multi-variable coupling and dynamic of plastic injection molding process, an intelligent modeling methodology based on partial least-squares (PLS) regression and neural networks (NN) was presented to predict the quality index of injection-molded parts in this study. This modeling approach extracted relatively few latent variables as inputs of intelligent model by using correlation analysis and principle components extraction. Then a constructive approach and program was used to optimize training process and improve the precision of modeling. Furthermore, the performance of quality prediction model was evaluated and tested by its application to verification tests. Compared with normal neural networks, PLS-NN model has better prediction performance and generalization ability, the simulation result proved that this approach was effective.

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Ahmad, Faiz, Ali Samer Muhsan, and M. Rafi Raza. "Rheological Behavior of Carbon Nanotubes / Copper Feedstocks for Metal Injection Molding." Advanced Materials Research 403-408 (November 2011): 5335–40. http://dx.doi.org/10.4028/www.scientific.net/amr.403-408.5335.

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Metal injection molding (MIM) technology is known for its ability of producing near net shape components. This study presents the results of flow behavior of multi-walled carbon nanotubes (MWCNTs) reinforced copper composites mixes. The solid loadings in the copper mixes were investigated in the ranges of 55-61 V% using a binder. Copper mixes and copper/MWCNTs were compounded using a Z-blade mixer for homogenous dispersion of solids in the binder. Results identified a mix containing 59 V% copper suitable for substitution of MWCNTs. The flow properties were measured using a capillary rheometer in the shear rate range expected to occur during metal injection molding. An increasing trend in viscosity of the copper mixes with powder loading was noted. Copper/MWCNTs composite mixes showed viscosity more than 1000 Pa.s perhaps due to addition of MWCNTs and increasing trend in viscosity of copper/MWECNTs was recorded. The results of flow data showed that all copper composite mix containing up to 10 Vol.% MWCNTs were successfully injection molding and test samples were produced.

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Sreedharan, J., AK Jeevanantham, and A. Rajeshkannan. "Multi-objective optimization for multi-stage sequential plastic injection molding with plating process using RSM and PCA-based weighted-GRA." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 234, no. 5 (November 15, 2019): 1014–30. http://dx.doi.org/10.1177/0954406219887993.

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The multi-stage sequential process with multi-objective is a complex problem to address as the decision made at a particular stage influences the subsequent stage and vice versa. In this article, the effects of input variables of plastic injection, mold, and different plating stages were investigated on different output responses, namely weldline, warpage, length, and various metal plating thicknesses. This paper investigates a real-time industrial data of manufacturing an automotive exterior part made of ABS material. A D-optimal experimental layout with 55 experiments was generated for eight input factors each at three levels. Nine different output responses in each experiment were normalized into a weighted grey relational grade using grey relational analysis coupled with principal component analysis. The solutions obtained by the analysis of variance on weighted grey relational grade, and by the desirability analysis of D-optimal were compared and validated. The confirmation experiments recorded an average improvement in cumulative process outputs as 40.56% by grey relational analysis and 38.50% by desirability analysis.

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Yang, Gui Rong, Jing Li, Wen Ming Song, Jun Hu Meng, and Ying Ma. "Mixing Behavior and Flowing Property in Micro-Powder Injection Molding of Carbonyl Steel Feedstock." Advanced Materials Research 753-755 (August 2013): 167–70. http://dx.doi.org/10.4028/www.scientific.net/amr.753-755.167.

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A feedstock consisting of carbonyl steel powder and multi-component binder was developed for powder injection molding (PIM), and the mixing behavior of feedstock was investigated under different powder loading, different temperature and different binder systems. The thermal and rheological properties were investigated. The results showed that the torque of feedstock could reach a steady state in s short time of 90 min when the loading powder was 52%. The torque of feedstock at 160°C was lower than that at 150 °C before the heating time was less 90 min. The torque of feedstock could reach steady state level in a short time of 90 min when the content of SA was 10%. SA served as surface-active agent that reduced the mixture viscosity and increased the solids content of the mixture by creating an interfacial bridge between the powder and the binder. The viscosity of feedstock decreased with increasing shear rate and temperature because the agglomerations between particles were eliminated owing to the movement.

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Islam, Syed Humail, Xuan Hui Qu, and M. Tufail. "Preparation and Characterization of Tungsten Heavy Alloy Feedstock for Metal Injection Molding." Advanced Materials Research 26-28 (October 2007): 363–66. http://dx.doi.org/10.4028/www.scientific.net/amr.26-28.363.

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In this study, the effect of various binders’ compositions on the feedstock of pre-alloyed tungsten heavy alloys (WHAs) powders has been investigated. Four kinds of wax-based binders were prepared from paraffin wax (PW), high-density polyethylene (HDPE), polypropylene (PP) and stearic acid (SA), and the characteristic of each feedstock was investigated at various temperatures and shear rates. It was found that all the feedstocks exhibited pseudoplastic flow behavior. Feedstock having multi-polymer components showed better rheological properties than those having mono-polymer because of good wettability between powder and binder, and less sensitivity to temperature and shear rates. This could be due to the molecular weight and length of molecular chain of PP and HDPE.

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Braga, Ion Cristian, Razvan Udroiu, and Anisor Nedelcu. "Improving the laser engraving quality of padpainted and spray-painted mechatronic devices." MATEC Web of Conferences 299 (2019): 06004. http://dx.doi.org/10.1051/matecconf/201929906004.

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Considering the cost reduction in automotive processes, in the case of mechatronic devices that use2-3 colours for symbols, a solution is to replace the multi-component molding injection with the painting of a white component substrate in different colours. However, combined painting techniques, namelypad-painting and spray-painting, can lead to many risks, especially when those symbols are obtained bylaser etching, so removing the final paint layer to let only the first coloured layer be visible. The paper's aim is to present the analysis and reduction of the variation due to the different thickness of the coating layers as well as their drying level by using the ultrasonic measuring techniques and the optical microscopy cross-section to reduce the over-adjusting of the engraving parameters and to improve the final quality of the symbols.

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Mahshid, Rasoul, Yang Zhang, Hans Nørgaard Hansen, and Alexander Henry Slocum. "Effect of mold compliance on dimensional variations of precision molded components in multi-cavity injection molding." Journal of Manufacturing Processes 67 (July 2021): 12–22. http://dx.doi.org/10.1016/j.jmapro.2021.04.048.

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Calaon, Matteo, Federico Baruffi, Gualtiero Fantoni, Ilenia Cirri, Marco Santochi, Hans Nørgaard Hansen, and Guido Tosello. "Functional Analysis Validation of Micro and Conventional Injection Molding Machines Performances Based on Process Precision and Accuracy for Micro Manufacturing." Micromachines 11, no. 12 (December 16, 2020): 1115. http://dx.doi.org/10.3390/mi11121115.

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Micro polymer parts can be usually manufactured either by conventional injection moulding (IM) or by micro-injection moulding (µIM). In this paper, functional analysis was used as a tool to investigate the performances of IM and µIM used to manufacture the selected industrial component. The methodology decomposed the production cycle phases of the two processes and attributed functions to parts features of the two investigated machines. The output of the analysis was aimed to determine casual chains leading to the final outcome of the process. Experimental validation of the functional analysis was carried out moulding the same micro medical part in thermoplastic elastomer (TPE) material using the two processes by means of multi-cavity moulds. The produced batches were assessed using a precision scale and a high accuracy optical instrument. The measurement results were compared using capability indexes. The data-driven comparison identified and quantified the correlations between machine design and part quality, demonstrating that the µIM machine technology better meets the accuracy and precision requirements typical of micro manufacturing productions.

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Zang, Ming Xiang, Ting Wang, Chen Liu, and Yong Rui Zhao. "Optimization Design of Stack Package Warpage Based on Moldflow Software." Advanced Materials Research 605-607 (December 2012): 34–37. http://dx.doi.org/10.4028/www.scientific.net/amr.605-607.34.

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Currently, 3D multi-chip stack assembly is becoming the future development direction of advanced manufacturing process for printed circuit board. However, during the process of Components stacked packages, Warpage control of chips in the reflow soldering is particularly important. By Combining Taguchi method and injection molding simulation software – Moldflow, this paper studied FBGA and PBGA warpage deformation in the POP, setted four design factors, such as the mold temperature, melt temperature, injection pressure and injection time , find out the minimum warpage combination of design and critical design factors affecting the warpage. Then the factors are ranked according to the degree of the impact of the above experiments. The best combination of levels for these factors is getted, the stacked package parameter is optimized. Experiments show that the value of warpage decreased significantly.

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Oelsch, Erik, Ralf Landgraf, Lysander Jankowsky, Martin Kausch, Stefan Hoyer, Welf-Guntram Drossel, and Jörn Ihlemann. "Comparative investigation on the mechanical behavior of injection molded and 3D-printed thermoplastic polyurethane." Journal of Rubber Research 24, no. 2 (March 26, 2021): 249–56. http://dx.doi.org/10.1007/s42464-021-00092-w.

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Abstract3D printing opens up new possibilities for the production of polymeric structures that would not be possible with injection molding. However, it is known that the manufacturing method might have an impact on the mechanical properties of manufactured components. To this end, the mechanical behavior of test specimens made of thermoplastic polyurethane is compared for two different manufacturing methods. In particular, the SEAM technology (screw extrusion additive manufacturing) is compared to a conventional injection molding process. Uniaxial tension test specimens from both manufacturing methods are analyzed in two testing sequences (multi-hysteresis tests to analyze inelastic properties and uniaxial tension until rupture). To get as less perturbation as possible, the 3D-printed samples are printed with only one strand per layer. Moreover, a correction approach based on optical measurements is applied to determine the true cross-sectional area of the test specimens. The mechanical tests reveal that the inelastic material behavior is the same for both manufacturing methods. Instead, 3D-printed specimens show lower maximal stretch values at rupture and an increased variance in the results, which is related to the surface structure of 3D-printed specimens.

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Ou, Hui Bin, Mohamed Sahli, Thierry Barrière, and J. C. Gelin. "Adhesion Strength Study of Silicone Rubber Compounds to Nylon 66." Key Engineering Materials 622-623 (September 2014): 453–58. http://dx.doi.org/10.4028/www.scientific.net/kem.622-623.453.

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In recent years, multi-component injection molding has largely developed in the industries. During the manufacturing process, the critical challenge is in achieving an optimum adhesion between the two materials. This study examines the influence of curing kinetics on the interfacial adhesion strength between a silicone rubber and nylon 66 using a rotational rheometer. The evolution of adhesion strength of assembly during the curing behaviour of silicone rubber was measured by tensile test at different curing temperature and different curing time. The results showed a significant increase in adhesion was obtained while either the curing temperature or the curing time increased. In this study, the rheological property of silicone rubber fluid has been also determined by the rotational rheometer. In addition, the kinetics of the curing reaction of silicone rubber has been studied by differential scanning calorimeter.

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Seemüller, C., M. Heilmaier, T. Hartwig, M. Mulser, N. Adkins, and M. Wickins. "Influence of microstructure and processing on mechanical properties of advanced Nb-silicide alloys." MRS Proceedings 1516 (2012): 317–22. http://dx.doi.org/10.1557/opl.2012.1655.

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ABSTRACTIn this study different powder metallurgical processing routes, commonly used for refractory metal based materials, were evaluated on their impact on mechanical properties of a multi-component Nb-20Si-23Ti-6Al-3Cr-4Hf (at.%) alloy. Powder was produced by gas-atomization or high energy mechanical alloying of elemental powders and then consolidated either by HIPing or powder injection molding (PIM). The PIM process requires fine particles. In this investigation powder batches of gas-atomized powder (< 25 μm) and mechanically alloyed powder (< 25 μm) were compacted via PIM. Fine (< 25 μm) and coarser (106-225 μm) particle fractions of gas-atomized powder were compacted via HIPing for comparison. Quantitative analysis of the resulting microstructures regarding porosity, phase formation, phase distribution, and grain size was carried out in order to correlate them with the ensuing mechanical properties such as compressive strength at various temperatures.

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Simon, Erik P., Moritz Fröhlich, Ch Kallmayer, and K. D. Lang. "Design and Optimization of an Injection-Moldable Force-Fit Interconnection Module for Smart Textile Applications." Advances in Science and Technology 80 (September 2012): 96–101. http://dx.doi.org/10.4028/www.scientific.net/ast.80.96.

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This work presents a polymer based force-fit interconnection module (Click-Bond) that can be used to establish reliable electrical and mechanical interconnections between electronic components and textile circuit boards at room temperature. It is an extremely fast and cost-efficient process that is able to bring smart textile applications into the mass market. The semi-crystalline polymer POM-C is selected as material. It has good physical properties and can be used in injection molding. After the design is made mechanical experiments are performed to analyze the maximum forces and stress relaxation of the modules. Additionally, the compressibility of fabrics is analyzed to be able to design the module to apply a certain pressure. Finally, a multi-terminal board is presented that allows to easily integrate more complex electronics boards into smart textiles.

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Putra, Kurniawan Purnama, and R. Koekoeh R. W. "OPTIMASI PRODUKSI TUTUP BOTOL 500 ml PADA PROSES INJECTION MOULDING MENGGUNAKAN METODE RESPONSE SURFACE." ROTOR 10, no. 1 (April 1, 2017): 36. http://dx.doi.org/10.19184/rotor.v10i1.5146.

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Injection molding is one of the most common operations and versatile for mass production of complex plastic components. Injection molding is a process of plastic forming into a desired shape by means of pressing molten plastic into a space (cavity). Injection molding has a multi-step process, starting from inserting plastic pellets into the hopper, then plastic pellets into barrels / heating which makes the plastic material is melted. Melting plastic material is driven by the rotation of the screw, so that the flow to the nozzle, and then toward the sprue, runner, gate and into the cavity. Then the material present in the cavity will be retained within the mold under a certain pressure (holding pressure) to keep no shringkage when the product cooling process (cooling).The purpose of this study was to obtain the optimization of the cycle time and the percentage of production reject the bottle cap 500 ml in PT Berlina Tbk. The method used for this research is the method of response surface analysis, method surface respone is statistical and mathematical methods used to examine the relationship between one or more variables with the qualitative form of the response variables that aims to optimize and develop the response in an experiment. The data is optimized using Minitab software 16 produces an output response parameter setting optimization to inject pressure, nozzle temperature and cooling time. From the data analysis using the software Minitab 16 is obtained from the optimum situation results generated under conditions injection amounting to 1420 bar pressure; nozzle temperature at 264.7912 ° C; and the cooling time of 14.08 seconds. In this state of production can be increased by 10.836%. From the state of the optimum cycle time generated is 27.9161 seconds, net produced according to the standard that is 33.5820 grams and reject percentage the resulting is 11.11%. With a cycle time 27.9161 seconds with a net according to the standard and the percentage of rejects decreased 3.89%, the resulting product amounts to ± 15,517 /shift or up approximately 10.836%. The amount is based on the number of products produced in the cycle time previous of 30 seconds to produce ± 14,000 /shift. Keywords: Injection moulding, box-benhken design, Response surface methodology

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Viana, Júlio C., and Lyudmil Todorov. "Structure-Properties Relationships in Processed Poly(ethylene terephthalate)." Key Engineering Materials 554-557 (June 2013): 1757–62. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.1757.

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Abstract. Upon processing, polymeric products feature a complex microstructure. Besides evolving over the molded component, a through-the-thickness variation is also developed. This is the result of the thermo-mechanical environment (combined thermal and mechanical fields) applied during processing, which varies with the molding technique, the selected molding conditions and polymer properties (rheological, thermal, constitution). This complex microstructure makes rather intricate the establishment of structure-properties relationships in processed polymers. In fact, the basic identification of most relevant morphological parameters determining the behavior of the moldings is been revealed a difficult endeavor, further complicated by the multi-scale morphology presented by polymeric materials. This work follows an inductive approach for establishing the relationships between the structure and the properties (mechanical and barrier) of molded poly(ethylene terephthalate), PET. These relationships are investigated for specimens prepared by different methods, from “simple” to more “complex” stretching modes. Initially, PET specimens were prepared by stretching thin films at different high temperatures and strain rates, followed by quick cooling in a universal testing machine equipped with a thermal camera (uniaxial stretched specimens). More closely to processing, PET injection molded preforms were free blown without a mold with distinct conditions (free blown specimens). Finally, PET bottles were produced from the preforms also under different blown conditions. The morphology of all specimens was assessed by bi- and tri-refringence and DSC. The mechanical properties were evaluated by tensile tests at room temperature. Also, the oxygen transmission rate, OTR, was assessed for the PET bottles. For this low crystallinity and slowly crystallizable polymer, the initial modulus is mainly related to the amorphous phase (i.e., molecular mobility and orientation level). The yield stress appears to be determined by the degree of crystallinity and level of molecular orientation. In the case of free blown specimens (bi-axially stretched) the anisotropy of the initial modulus depends upon the induced anisotropy of the molecular orientation. OTR is influenced by the molecular orientation and the degree of crystallinity of the polymer. An attempt to interpret these types of relationships by molecular dynamics simulations is made.

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Carlone, Pierpaolo, and Gaetano S. Palazzo. "A Micro-Scale Model for Fiber Tow Characterization under Nondeterministic Assumption: Longitudinal and Transverse Permeability." Key Engineering Materials 554-557 (June 2013): 2348–54. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.2348.

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Liquid Composite Molding processes are characterized by the impregnation of a dry fibrous perform by means of injection or infusion of a catalyzed resin. In recent years computational flow and cure models allowed for a remarkable time and cost compression in process planning with respect to trial and error procedures. In this contest multi-scale simulative approaches are gaining considerable attention and intriguing results have been recently presented. Most of the proposed models, however, rely on deterministic hypothesis, assuming perfect fiber packing and neglecting dimensional variations between fibers, in strong contrast with experimental observations. In this paper the influence of the stochastic variability of the fiber packing on tow permeability has been investigated by means of a CFD micro scale model. The variability of the microstructure defining the Representative Volume Element has been considered introducing random perturbations of the fiber packing. The components of the permeability tensor, in each case, have then been derived applying the Darcy model to flow simulations through the representative cell.

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Chi, Baihong, Zhiwei Jiao, and Weimin Yang. "Design and experimental study on the freeform fabrication with polymer melt droplet deposition." Rapid Prototyping Journal 23, no. 3 (April 18, 2017): 633–41. http://dx.doi.org/10.1108/rpj-03-2015-0028.

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Purpose 3D printing based on additive manufacturing has advantages in manufacturing products with high geometrical complexity. However, there are many limitations to print plastic products with the existing commercial 3D printers. The polymer materials processing industry needs new devices which can satisfy the trend of processing individual units and small batch sizes of plastic parts. Design/methodology/approach In this study, a freeform fabrication system with the method of polymer melt droplet deposition is proposed. The performance of this system under different conditions was studied by changing the operating parameters. Furthermore, the dimensional uniformity of droplets and their deposition process are analyzed, and a plastic sample was fabricated with this system as an example. Findings The results show a clear correlation between the processing parameters and the droplet diameter. In the experiment for examining the dimensional uniformity of the droplet, the droplets become spindles, and there appears a melt filament between the droplets. The variation of the droplet’s diameters is within 5 per cent. Furthermore, a successfully processed rectangular plastic sample verified the feasibility of this technology for the printing of plastic products. Originality/value A freeform fabrication system with polymer melt droplet deposition is proposed, which can process a wide variety of materials in the form of standard granulates like injection molding or extrusion. Based on the principle of droplet deposition, multi-component or colorful materials can be printed.

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Stier, Simon P., and Holger Böse. "Ablative Laser Structuring for Stretchable Multilayer and Multi-Material Electronics and Sensor Systems." Proceedings 56, no. 1 (December 17, 2020): 21. http://dx.doi.org/10.3390/proceedings2020056021.

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Conventional machining and shaping processes for polymers and elastomers such as injection molding exhibit significant disadvantages, as specific tools have to be manufactured, the method of machining is highly dependent on the material properties, and the cost of automation is usually high. Therefore, additive manufacturing processes (3D printing) have established themselves as an alternative. This eliminates the expensive production of tools and the production is individualized. However, the specific (additive) manufacturing process remains highly dependent on the properties of the material. These processes include selective laser sintering (SLS) for powdered thermoplastic polymers and metals, extrusion such as fused deposition modeling (FDM) for thermoplastic polymers in wire form, or optical curing such as digital light processing (DLP) for liquid resins. Especially for elastomer sensors or circuit boards (structure of several alternately constituted approx. 100 µm-thick elastomer films made with different types of liquid silicone rubber), there is no suitable additive manufacturing process that combines liquid, partly non-transparent source materials, multi-component printing, and very fine layer thicknesses. In order to enable a largely automated, computer-aided manufacturing process, we have developed the concept of ablative multilayer and multi-material laser-assisted manufacturing. Here, the layers (conductive and non-conductive elastomers, as well as metal layers for contacting) are first coated over the entire surface (e.g., spray, dip, or doctor blade coating, as well as galvanic coating) and then selectively removed with a CO2 or fiber laser. These steps are repeated several times to achieve a multi-layer structured design. Is it not only possible to adjust and improve the work previously carried out manually, but also to introduce completely new concepts, such as fine through-plating between the layers to enable much more compact structures to be possible. As an exemplary application, we have used the process for manufacturing a thin and surface solderable pressure sensor and a stretchable circuit board.

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Agüero, Ángel, David Garcia-Sanoguera, Diego Lascano, Sandra Rojas-Lema, Juan Ivorra-Martinez, Octavio Fenollar, and Sergio Torres-Giner. "Evaluation of Different Compatibilization Strategies to Improve the Performance of Injection-Molded Green Composite Pieces Made of Polylactide Reinforced with Short Flaxseed Fibers." Polymers 12, no. 4 (April 4, 2020): 821. http://dx.doi.org/10.3390/polym12040821.

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Green composites made of polylactide (PLA) and short flaxseed fibers (FFs) at 20 wt % were successfully compounded by twin-screw extrusion (TSE) and subsequently shaped into pieces by injection molding. The linen waste derived FFs were subjected to an alkalization pretreatment to remove impurities, improve the fiber surface quality, and make the fibers more hydrophobic. The alkali-pretreated FFs successfully reinforced PLA, leading to green composite pieces with higher mechanical strength. However, the pieces also showed lower ductility and toughness and the lignocellulosic fibers easily detached during fracture due to the absence or low interfacial adhesion with the biopolyester matrix. Therefore, four different compatibilization strategies were carried out to enhance the fiber–matrix interfacial adhesion. These routes consisted on the silanization of the alkalized FFs with a glycidyl silane, namely (3-glycidyloxypropyl) trimethoxysilane (GPTMS), and the reactive extrusion (REX) with three compatibilizers, namely a multi-functional epoxy-based styrene-acrylic oligomer (ESAO), a random copolymer of poly(styrene-co-glycidyl methacrylate) (PS-co-GMA), and maleinized linseed oil (MLO). The results showed that all the here-tested compatibilizers improved mechanical strength, ductility, and toughness as well as the thermal stability and thermomechanical properties of the green composite pieces. The highest interfacial adhesion was observed in the green composite pieces containing the silanized fibers. Interestingly, PS-co-GMA and, more intensely, ESAO yielded the pieces with the highest mechanical performance due to the higher reactivity of these additives with both composite components and their chain-extension action, whereas MLO led to the most ductile pieces due to its secondary role as plasticizer for PLA.

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Lee, Dan Bi, Yun Hyo Nam, and Min-Young Lyu. "Comparison of Molding Characteristics for Multi-cavity Molding in Conventional Injection Molding and Injection Compression Molding." Polymer Korea 38, no. 2 (March 25, 2014): 144–49. http://dx.doi.org/10.7317/pk.2014.38.2.144.

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Teodorescu, George Mihail, Zina Vuluga, Mariana Osiac, Nicoleta Levinta, Cristian Andi Nicolae, Raluca Augusta Gabor, Andreea Afilipoaei, and Mihai Cosmin Corobea. "Injection Molding and Compression Molding of Polyamide 10.10." Proceedings 57, no. 1 (November 11, 2020): 51. http://dx.doi.org/10.3390/proceedings2020057051.

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Fuji, Saburo. "Injection Molding of Multi-micro Holes." Seikei-Kakou 10, no. 4 (1998): 252–57. http://dx.doi.org/10.4325/seikeikakou.10.252.

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Chen, Jyun Yi, and Wen Bin Young. "Two-Component Injection Molding of Molded Interconnect Devices." Advanced Materials Research 628 (December 2012): 78–82. http://dx.doi.org/10.4028/www.scientific.net/amr.628.78.

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Molded Interconnect Device (MID) can be defined as that an injection-molded plastic part combining with electrical and mechanical functions in a single device. This study is to examine the application of micro injection molding technology to the two-component molding process for the MID fabrication. The process involves the first shot of a plastic component with channel patterns on the surface. A second shot by micro injection molding technology is applied to fill the channel with the plateable plastics. The effects of the micro injection molding process parameters on filled line width of the two-component MID will be investigated. It is concluded that, for a MID component, the molding conditions must be designed carefully to keep the thickness variation below the allowable value. It is also found from the experiments that the thickness interference may in the range from 92 m to 196 m to have adequate molding at the second shot.

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Keestra, B. J., P. D. Anderson, and H. E. H. Meijer. "Two Component Injection Molding of Phase Separating Blends." International Polymer Processing 21, no. 2 (May 2006): 168–74. http://dx.doi.org/10.3139/217.1907.

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Nishio, Taichi, and Takahisa Hara. "Injection Molding Processing-Flow Behaivour of Multi-Phase Polymer Systems for Injection Molding and Low Presure/Low Strain Molding Process "SP Molding"." Kobunshi 42, no. 9 (1993): 740–45. http://dx.doi.org/10.1295/kobunshi.42.740.

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Ilinca, Florin, and Jean-Françlois Hétu. "Three-dimensional simulation of multi-material injection molding: Application to gas-assisted and co-injection molding." Polymer Engineering & Science 43, no. 7 (July 2003): 1415–27. http://dx.doi.org/10.1002/pen.10120.

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Jeon, Jin Woo, Jeong Hwan Yun, Myeong Sik Jeong, Yang Gon Kim, Hoon Jae Park, Gi Man Bae, and Ji Hyun Sung. "Metal Powder Injection Molding Process for Manufacturing Adapter Component." Key Engineering Materials 622-623 (September 2014): 868–75. http://dx.doi.org/10.4028/www.scientific.net/kem.622-623.868.

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Adapters are a component of the output system in the internally geared hub for a bicycle. Originally, adapter parts were produced by a machining process with low productivity and material usage rate. In this study, the metal powder injection molding (MIM) process has been applied as an alternative manufacturing method to the machining process. Microstructure analysis and mechanical property testing has been conducted in order to select the material for the adapter with changes in the nickel content. The geometrical precision of the adapter is measured by using three-dimensional scanner with various mixing ratios of the powder and the binder. The developed alternative process for the adapter results in increased productivity and material usage rate. Previously, this process was only used for small parts less than 10 mm in diameter. With this development, the MIM process may be used more widely than before.

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Bräuer, M., B. Hupfer, J. Nagel, and D. Lehmann. "Chemical modification of polyurethane for two-component injection molding." Polymer Engineering & Science 42, no. 4 (April 2002): 859–69. http://dx.doi.org/10.1002/pen.10997.

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Park, Hong-Seok, and Dinh Ba Hung Anh. "A new approach for molding multi component parts." International Journal of Precision Engineering and Manufacturing 11, no. 2 (April 2010): 291–97. http://dx.doi.org/10.1007/s12541-010-0033-0.

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ZHANG, Kai, Zhengying LIU, Nan SUN, Long WANG, Bin YANG, Ying LU, and Mingbo YANG. "CRYSTAL MORPHOLOGY OF HDPE MOLDED BY MULTI-FLUID MULTI-INJECTION MOLDING." Acta Polymerica Sinica 011, no. 3 (March 23, 2011): 235–39. http://dx.doi.org/10.3724/sp.j.1105.2011.10325.

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Shang Guan, Lin Jian, Yang Yang, and Jie Yang. "Double Scale Coupling Model of Plastic Injection Molding." Advanced Materials Research 472-475 (February 2012): 2148–51. http://dx.doi.org/10.4028/www.scientific.net/amr.472-475.2148.

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The process of short fiber reinforced injection molding is a typical multi-scale problem, it has become a cutting-edge issue of the field of polymer molding to study clearly the mesoscopic structure changing rules in the whole molding processing. Aiming at the processing of glass fiber reinforced polypropylene injection, basing on the foundation of macro continuum medium model, approximated short fiber reinforced injection molding process as macro-mesoscopic double scale problem composed by macro-flow and small-scale short fiber movement, establish the double scale model, which couple Mesoscopic fiber orientation. And the cooling crystallization model was established by learning from multi-scale simulation of liquid metal crystallization method.

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Yunn, Heng Shye, Norhamidi Muhamad, and Abu Bakar Sulong. "Micro Powder Injection Molding (µPIM): Review." Applied Mechanics and Materials 52-54 (March 2011): 91–96. http://dx.doi.org/10.4028/www.scientific.net/amm.52-54.91.

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Micro powder injection molding (µPIM) is the combination of micro injection molding and powder injection molding (PIM) technology. The increasing demands on market of microparts further intensify the development of this technology. µPIM process enables the use of a wide range of materials and broadens the applications of micro components. This process is well suitable for large volume production of micro-components at low costs. Requirement of powder and binder is more stringent since product fabricate in micron scale, therefore criterion of the powder and binder has been reviewed in this paper. In addition, the process parameter and development in the computer aid plays an important due to the narrow process window requires even tighter as the quality of the micro-component is sensitive to the parameter. This paper outlines recent development in µPIM. Challenges and further explore for µPIM is concluded in the last part of this paper.

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NATSUME, Shinji, and Satoshi KITAYAMA. "Multi-objective optimization in plastic injection molding with injection and packing time." Transactions of the JSME (in Japanese) 81, no. 830 (2015): 15–00028. http://dx.doi.org/10.1299/transjsme.15-00028.

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Tang, Li Q., Constantin Chassapis, and Souran Manoochehri. "Optimal cooling system design for multi-cavity injection molding." Finite Elements in Analysis and Design 26, no. 3 (June 1997): 229–51. http://dx.doi.org/10.1016/s0168-874x(96)00083-2.

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Choi, Sung-Joo, and Sun Kyoung Kim. "Multi-scale filling simulation of micro-injection molding process." Journal of Mechanical Science and Technology 25, no. 1 (January 2011): 117–24. http://dx.doi.org/10.1007/s12206-010-1025-9.

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Journal articles on the topic 'Multi component injection molding'

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