Improved contact lens injection molding production by 3D printed conformal cooling channels

2017 ◽  
Author(s):  
Y.F. Lin ◽  
J.R. Wu ◽  
B.H. Liu ◽  
W. C. J. Wei ◽  
A. B. Wang ◽  
...  
Keyword(s):  
Injection Molding ◽  
Contact Lens ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
3D Printed

scholarly journals Integrated Optimum Layout of Conformal Cooling Channels and Optimal Injection Molding Process Parameters for Optical Lenses

2019 ◽  
Vol 9 (20) ◽  
pp. 4341 ◽  
Author(s):  
Chen-Yuan Chung
Keyword(s):  
Additive Manufacturing ◽  
Injection Molding ◽  
Process Parameters ◽  
Large Diameter ◽  
Melt Temperature ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Highly Efficient ◽  
Conformal Cooling Channels ◽  
Filling Time

Plastic lenses are light and can be mass-produced. Large-diameter aspheric plastic lenses play a substantial role in the optical industry. Injection molding is a popular technology for plastic optical manufacturing because it can achieve a high production rate. Highly efficient cooling channels are required for obtaining a uniform temperature distribution in mold cavities. With the recent advent of laser additive manufacturing, highly efficient three-dimensional spiral channels can be realized for conformal cooling technique. However, the design of conformal cooling channels is very complex and requires optimization analyses. In this study, finite element analysis is combined with a gradient-based algorithm and robust genetic algorithm to determine the optimum layout of cooling channels. According to the simulation results, the use of conformal cooling channels can reduce the surface temperature difference of the melt, ejection time, and warpage. Moreover, the optimal process parameters (such as melt temperature, mold temperature, filling time, and packing time) obtained from the design of experiments improved the fringe pattern and eliminated the local variation of birefringence. Thus, this study indicates how the optical properties of plastic lenses can be improved. The major contribution of present proposed methods can be applied to a mold core containing the conformal cooling channels by metal additive manufacturing.

scholarly journals Enhancing the Structural Strength for Injection Molding Tooling With Conformal Cooling Channels Using ANSYS Software

2021 ◽  
Author(s):  
Chil-Chyuan Kuo ◽  
Zheng-Yan You
Keyword(s):  
Injection Molding ◽  
Production Rate ◽  
Thermal Management ◽  
Structural Strength ◽  
Conformal Cooling Channel ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
Average Variation ◽  
Different Diameters

Abstract Injection molding of wax patterns faces increasing demands for production rate. Proper thermal management of the injection molding tooling is capable of improving the production rate. Precise temperature control is a key to shorten the cooling time using the conformal cooling channels which are conformal to the molding cavity. However, the service life of the injection molding tooling with cooling channels will reduce significantly because the structural strength will reduce obviously. In this study, the feasibility of applying the increase in the mold thickness to maintain the structural strength of the injection molding tooling with cooling channels was verified through simulation and experiments conducted. It was found that the average variation between the results of simulation and the experiment is about 24.9%. The approximately amount of the increase in the thickness required for different diameters of cooling channels can be determined according to the trend equation of y=1.3429x-2.3429. The results can provide a reference for the conformal cooling channel design.

scholarly journals Automatic design of conformal cooling channels in injection molding tooling

2018 ◽  
Vol 307 ◽  
pp. 012025 ◽  
Author(s):  
Yingming Zhang ◽  
Binkui Hou ◽  
Qian Wang ◽  
Yang Li ◽  
Zhigao Huang
Keyword(s):  
Injection Molding ◽  
Automatic Design ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels

scholarly journals A methodology for mould conformal cooling channels optimization exploiting 3D printing

2021 ◽  
Author(s):  
Edoardo Battista Arrivabeni ◽  
Daniele Tomasoni ◽  
Luca Giorleo ◽  
Maurizio Claudio Barbato
Keyword(s):  
3D Printing ◽  
Design Procedure ◽  
Optimization Procedure ◽  
Experimental Tests ◽  
Conformal Cooling ◽  
Testing Procedures ◽  
Cooling Channels ◽  
Conformal Cooling Channels ◽  
Push Forward ◽  
3D Printed

With the advent of 3D printing, it is now possible to produce any part or system with an approach than makes design much deeply interlaced with production. In this scenario, CAE has gained power thanks to the possibility of thinking and then manufacture ideas that go well beyond what was possible in the past. This design approach is perfectly suitable to push forward mould conformal cooling performance. In this work, a coupling of CAD, CFD and 3D printing supported by experimental tests was applied to define a design procedure for conformal cooling channels. In particular, cooling channels for a mould were engineered via CAD, then tested via CFD and, after an initial optimization procedure, the chosen design was 3D printed in specimens suitable to be mounted on a heat exchanger (HX) experimental test rig that was especially adapted for the scope. Fluids temperature, volume flow rates and heat transfer performance were measured. A feedback loop was considered to link measurements and channels redesign. Results together with design and testing procedures are reported and commented.

scholarly journals Structural Analysis of Molds with Conformal Cooling Channels: A Numerical Study

2021 ◽  
Author(s):  
Hugo Miguel Silva ◽  
Tiago Noversa ◽  
Hugo Rodrigues ◽  
Leandro Fernandes ◽  
António Pontes
Keyword(s):  
Injection Molding ◽  
Thermal Stresses ◽  
Numerical Study ◽  
Operating Conditions ◽  
Maximum Pressure ◽  
Injection Molding Process ◽  
Molding Process ◽  
Conformal Cooling ◽  
Cooling Channels ◽  
Conformal Cooling Channels

Abstract The manufacturing of Conformal cooling channels (CCC’s) is now easier and more affordable, owing to the recent developments in the field of additive manufacturing. The use of CCC’s allows better cooling performances than the conventional (straight-drilled) channels, in the injection molding process. The main reason is that CCC’s can follow the pathways of the molded geometry, while the conventional channels, manufactured by traditional machining techniques, are not able to. Using CCCs can significantly improve the cycle time, allow to obtain a more uniform temperature distribution, and reduce thermal stresses and warpage. However, the design process for CCC is more complex than for conventional channels. Computer-aided engineering (CAE) simulations are important for achieving effective and affordable design. This article presents important results regarding molds with new conformal cooling channels geometries. The aim is to assess the maximum pressure that the parts can be subjected to in a real injection molding application. Linear structural analyses are carried over in the Finite Element Method Software ANSYS Workbench 2020 R2, in order to analyze both the resistance and stiffness behavior of the studied geometries. The results are analyzed according to several metrics. The results were discussed and it could be concluded that some of the structures are suitable for the typical operating conditions of the injection molding process.

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