scholarly journals Manufacturing Signatures of Injection Molding and Injection Compression Molding for Micro-Structured Polymer Fresnel Lens Production

Micromachines ◽  
2018 ◽  
Vol 9 (12) ◽  
pp. 653 ◽  
Author(s):  
Dario Loaldi ◽  
Danilo Quagliotti ◽  
Matteo Calaon ◽  
Paolo Parenti ◽  
Massimiliano Annoni ◽  
...  
Keyword(s):  
Injection Molding ◽  
Laser Scanning ◽  
Injection Pressure ◽  
Fresnel Lens ◽  
Uncertainty Budget ◽  
Compression Molding ◽  
Process Conditions ◽  
Dimensional Measurements ◽  
Micro Features ◽  
Injection Compression Molding

Injection compression molding (ICM) provides enhanced optical performances of molded polymer optics in terms of birefringence and transmission of light compared to Injection molding (IM). Nevertheless, ICM requires case-dedicated process optimization to ensure that the required high accuracy geometrical replication is achieved, particularly especially in the case of surface micro-features. In this study, two factorial designs of experiments (DOE) were carried out to investigate the replication capability of IM and ICM on a micro structured Fresnel lens. A laser scanning confocal microscope was employed for the quality control of the optical components. Thus, a detailed uncertainty budget was established for the dimensional measurements of the replicated Fresnel lenses, considering specifically peak-to-valley (PV) step height and the pitch of the grooves. Additional monitoring of injection pressure allowed for the definition of a manufacturing signature, namely, the process fingerprint for the evaluation of the replication fidelity under different process conditions. Moreover, considerations on the warpage of parts were related to a manufacturing signature of the molding processes. At last, the global part mass average and standard deviation were measured to correlate local geometrical replication performances with global part quality trends.

A Study of Two-Stage Micro Injection Compression Molding Process for Diffractive Optical Lens

2007 ◽  
Vol 364-366 ◽  
pp. 1211-1214 ◽  
Author(s):  
Chao Chang Arthur Chen ◽  
Shi Chi Kao
Keyword(s):  
Mold Insert ◽  
Fresnel Lens ◽  
Compression Molding ◽  
Piezo Actuator ◽  
Molding Process ◽  
Spherical Lens ◽  
Two Stage ◽  
Optical Elements ◽  
Micro Features ◽  
Injection Compression Molding

This research aimed to develop a novel two-stage micro injection compression molding (μ-ICM) process for fabrication of plastic diffractive optic elements (DOE). The DOE was designed with the spherical coefficients and the Fresnel lens. A piezo actuator was installed inside the mold plate for activating the mold insert for the second compression motion for micro ICM of the DOE lens. The first experiment proceeded to find the operation window of Fresnel lens and then compare the product weight of flat spherical lens by injection molding (IM), injection compression molding (ICM) and μ-ICM. The second experiment was to investigate the effectiveness of micro compression activated by the piezo actuator by the transfer ratio of grooves (TRG) of the DOE lens with spherical lens and Fresnel lens. Results showed that the μ-ICM of the DOE can obtain the highest TRG than that of IM and conventional ICM processes. Therefore, results of this research can be explored to related aspheric optical elements with micro features, such as fine lens used in the zoom lens of camera.

Study on Optical Properties of Microstructure of Lightguiding Plate for Micro Injection Molding and Micro Injection-Compression Molding

2006 ◽  
Vol 505-507 ◽  
pp. 229-234 ◽  
Author(s):  
Yung Kang Shen ◽  
H.J. Chang ◽  
C.T. Lin
Keyword(s):  
Optical Properties ◽  
Injection Molding ◽  
Digital Camera ◽  
Mold Temperature ◽  
Compression Molding ◽  
Micro Injection Molding ◽  
Melt Temperature ◽  
Packing Pressure ◽  
Injection Compression Molding ◽  
Better Than

The purpose of this paper presents the optical properties of microstructure of lightguiding plate for micro injection molding (MIM) and micro injection-compression molding (MICM). The lightguiding plate is applied on LCD of two inch of digital camera. Its radius of microstructure is from 100μm to 300μm by linearity expansion. The material of lightguiding plate uses the PMMA plastic. This paper uses the luminance distribution to make a comparison between MIM and MICM for the optical properties of lightguiding plate. The important parameters of process for optical properties are the mold temperature, melt temperature and packing pressure in micro injection molding. The important parameters of process for optical properties are the compression distance, mold temperature and compression speed in micro injection-compression molding. The process of micro injection-compression molding is better than micro injection molding for optical properties.

Effect of Processing Conditions on the Shrinkage and Warpage of Glass Fiber Reinforced PP Using Microcellular Injection Molding

2012 ◽  
Vol 501 ◽  
pp. 294-299 ◽  
Author(s):  
Zhi Bian ◽  
Peng Cheng Xie ◽  
Yu Mei Ding ◽  
Wei Min Yang
Keyword(s):  
Injection Molding ◽  
Glass Fiber ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Process Conditions ◽  
Fiber Reinforced ◽  
Injection Speed ◽  
Glass Fiber Reinforced ◽  
Microcellular Injection Molding ◽  
Molded Parts

This study was aimed at understanding how the process conditions affected the dimensional stability of glass fiber reinforced PP by microcellular injection molding. A design of experiments (DOE) was performed and plane test specimens were produced for the shrinkage and warpage analysis. Injection molding trials were performed by systematically adjusting six process parameters (i.e., Injection speed, Injection pressure, Shot temperature, SCF level, Mold temperature, and Cooling time). By analyzing the statistically significant main and two-factor interaction effects, the results showed that the supercritical fluid (SCF) level and the injection speed affected the shrinkage and warpage of microcellular injection molded parts the most.

Reduction in Defect Rate by Taguchi Method in Plastic Injection Molded Components

2012 ◽  
Vol 488-489 ◽  
pp. 269-273 ◽  
Author(s):  
G.S. Dangayach ◽  
Deepak Kumar
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Processing Parameters ◽  
Process Conditions ◽  
Melt Temperature ◽  
Defect Rate ◽  
Packing Pressure ◽  
Optimal Injection ◽  
Packing Time ◽  
Plastic Injection

In the present era, competition gets tougher; there is more pressure on manufacturing sectors to improve quality and customer satisfaction while decreasing cost and increasing productivity. These can be achieved by using modern quality management systems and process improvement techniques to reduce the process variability and driven waste within manufacturing process using effective application of statistical tools. Taguchi technique is well known technique to solve industrial problems. This technique is fast and can pinpoint the chief causes and variations. Plastic injection molding is suitable for mass production articles since complex geometries can be obtained in a single production step. The difficulty in setting optimal process conditions may cause defects in parts, such as shrinkage and warpage. In this paper, optimal injection molding conditions for minimum shrinkage were determined by the Taguchi design of experiment (DOE) approach. Polypropylene (PP) was injected in circular shaped specimens under various processing parameters: melt temperature, injection pressure, packing pressure and packing time. S/N ratios were utilized for determining the optimal set of parameters. According to the results, 2400 C of melt temperature, 75 MPa of injection pressure, 50 MPa of packing pressure and 15 sec. of packing time gave minimum shrinkage of 0.951% for PP. Statically the most significant parameter was melt temperature for the PP. Injection pressure had the least effect on the shrinkage. The defect rate was reduced from 14% to 3%.

Restraint of Voids Generated Inside Injection Molded Products by In-Mold Pressing Method

2018 ◽  
Vol 12 (6) ◽  
pp. 930-939 ◽  
Author(s):  
Atsushi Motegi ◽  
Tomohiro Hishida ◽  
Yasuhiko Murata ◽  
◽  
Keyword(s):  
Injection Molding ◽  
High Strength ◽  
Compression Molding ◽  
Fiber Reinforced ◽  
Pressing Method ◽  
Glass Fiber Reinforced Plastic ◽  
Fiber Reinforced Plastic ◽  
Reinforced Plastic ◽  
Injection Molded ◽  
Injection Compression Molding

In recent years, long glass fiber reinforced plastic and carbon fiber reinforced plastic have begun to be used for structural components that require high strength. As a result, thick-walled injection molded products are being manufactured. However, defects, known as voids, are generated inside the molded product and decrease the strength of the molded product, posing a significant problem at molding production sites. The partial compression method, which is a type of injection compression molding, is effective in preventing voids in thick-walled injection molding. However, there have been limited studies that comprehensively investigated the effects of the compression conditions on void prevention in thick-walled injection molding products or the shape and dimension of the molded product, or the issues in the molded product produced by applying compression. The authors have previously proposed the in-mold pressing (IMP) method, which allows the application of partial compression without the use of an injection compression molding machine and verified its validity. In this study, we proposed a compression device in which a servomotor-driven hydraulic pump actuator is used to propel a movable rod to apply compression to the melt inside the mold cavity. The IMP method using this device was applied to mold thick-walled products with thicknesses of 10 mm and greater, and the effects of compression on the generation of voids inside the molded product and the shape and dimensions of the product were investigated. The results indicate that the generation of voids can be prevented by application of this method. In addition, it was found that marginal deformations, which can pose issues, occur in the molded product when compressive stresses generated inside the molded product by compression are released after demolding.

Comparison of injection molding and injection/compression molding for the replication of microstructure

2015 ◽  
Vol 27 (4) ◽  
pp. 309-317 ◽  
Author(s):  
Seokkwan Hong ◽  
Jeongho Hwang ◽  
Jeongjin Kang ◽  
Kyunghwan Yoon
Keyword(s):  
Injection Molding ◽  
Compression Molding ◽  
Injection Compression Molding

scholarly journals Welding lines formation in holes obtained by low pressure injection molding of ceramic parts

Cerâmica ◽  
2018 ◽  
Vol 64 (369) ◽  
pp. 97-103 ◽  
Author(s):  
C. A. Costa ◽  
A. F. Michels ◽  
M. E. Kipper
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Low Pressure ◽  
Process Conditions ◽  
Injection Mold ◽  
Extraction Temperature ◽  
Post Injection ◽  
Injection Process ◽  
Pressure Injection

Abstract This work presents a study to evaluate the process of producing internal holes in ceramic disks produced by low pressure injection molding (LPIM) process. Two process conditions defined as pre-injection and post-injection were used to test the proposition. In the first one the pin cores that produce the holes were positioned in the cavity before the injection of the feedstock; and in the second one, the pin cores were positioned in the cavity, just after the feeding phase of the injection mold. An experimental injection mold designed and manufactured to test both processes was developed to produce ceramic disk with Ø 50 x 2 mm with four holes of Ø 5 mm, equally and radially distributed through the disk. The feedstock was composed of 86 wt% alumina (Al2O3) and 14 wt% organic vehicle based on paraffin wax. Heating and cooling systems controlled by a data acquisition system were included in the mold. The results showed that there were no welding lines with the post-injection process, proving to be an option for creating holes in the ceramic parts produced by LPIM. It was observed that best results were obtained at 58 °C mold temperature. The pins extraction temperature was about 45 °C, and the injection pressure was 170 kPa.

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