scholarly journals Enabling Micro Injection Moulding Using a Soft Tooling Process Chain with Inserts Made of Mortar Material

Micromachines ◽  
2021 ◽  
Vol 12 (8) ◽  
pp. 857
Author(s):  
Kilian Krüger ◽  
Martin Kain ◽  
Yang Zhang ◽  
David Bue Pedersen ◽  
Matteo Calaon ◽  
...  
Keyword(s):  
Rapid Prototyping ◽  
Injection Moulding ◽  
Acrylonitrile Butadiene Styrene ◽  
Qr Code ◽  
Process Chain ◽  
Moulding Process ◽  
Micro Injection Moulding ◽  
Injection Moulding Process ◽  
Micro Features ◽  
Butadiene Styrene

The manufacturing of inserts for micro injection moulding made of mortar material is presented in this work. The fabrication of the mortar insert described in this publication relied on a versatile and relatively fast rapid prototyping process based on soft tooling. The mortar insert has a QR code with micro features on its surface, which was replicated in acrylonitrile butadiene styrene (ABS) polymer by the micro injection moulding process. With this approach, it is possible to fabricate hard inserts for micro injection moulding purposes that are able to compete with conventional-made inserts made of tool steel.

scholarly journals Process chain for serial manufacture of polymer components with micro- and nano-scale features: Optimisation issues

2016 ◽  
Vol 231 (11) ◽  
pp. 2000-2020
Author(s):  
Pierre C Vella ◽  
Stefan S Dimov ◽  
Alexander Kolew
Keyword(s):  
Metallic Glass ◽  
Bulk Metallic Glass ◽  
Injection Moulding ◽  
Length Scale ◽  
Process Chain ◽  
Moulding Process ◽  
Nano Scale ◽  
Micro Injection Moulding ◽  
Injection Moulding Process ◽  
Scale Integration

This article reports a follow-up research to investigate further the component technologies of a cost-effective manufacturing route designed to achieve function and length scale integration in products. The route employs a viable master-making process chain that integrates compatible and at the same time complementary, structuring and replication technologies to fabricate Zr-based bulk metallic glass inserts. To validate them, they are subsequently integrated into a micro-injection moulding machine, and polymer structures incorporating both micro- and nano-scale features are replicated. Especially, the masters and/or replicas after each processing step were analysed and the factors affecting its overall performance were identified. The research demonstrated that the master-making process chain can be a viable fabrication route for both fully amorphous and partially crystalline Zr-based bulk metallic glass inserts that incorporate different length scale features. The results also showed that relatively good fidelity of the different scale features can be achieved with the micro-injection moulding process, and thus, it can enable function and length scale integration in thermoplastic components.

Simulation of the micro-injection moulding process: effect of the thermo-rheological status on the morphology

2011 ◽  
Vol 225 (4) ◽  
pp. 224-238 ◽  
Author(s):  
T Nguyen-Chung ◽  
C Löser ◽  
G Jüttner ◽  
T Pham ◽  
M Obadal ◽  
...  
Keyword(s):  
Injection Moulding ◽  
Process Conditions ◽  
Transfer Coefficients ◽  
Moulding Process ◽  
Micro Injection Moulding ◽  
Mould Filling ◽  
Injection Moulding Process ◽  
Moulding Machine ◽  
Simulation Results ◽  
Micro Cavity

The software package Moldflow Plastics Insights was used to simulate the filling of a micro-cavity by considering precise material data and accurate boundary conditions. Experiments were carried out on an accurately controlled micro-injection moulding machine (formicaPlast) for providing important parameters to verify the simulation results and improve the accuracy of the simulation. Based on the relationship between the cavity pressure and the mould-filling ratio, the heat transfer coefficients can be appropriately determined for different process conditions. Finally, the transient thermo-rheological results were analysed with regard to their influence on the morphology of semi-crystalline (PP) micro-injection moulded parts, which not only give rise to the mechanisms of the morphological formation but also verify the quality of the simulation results.

Polymeric Micro-Filter Fabrication Using a Micro Injection Moulding Process

2015 ◽  
Author(s):  
Rossella Surace ◽  
Vincenzo Bellantone ◽  
Irene Fassi
Keyword(s):  
Injection Moulding ◽  
Electrical Discharge Machining ◽  
Polymeric Materials ◽  
Machining Process ◽  
Injection Velocity ◽  
Mould Temperature ◽  
Moulding Process ◽  
Micro Injection Moulding ◽  
Injection Moulding Process ◽  
Incomplete Filling

This paper reports on fabrication and characterization of a micro-filter for hearing aid, dialysis media and inhaler. The micro-feature specifications consist in a diameter of 2.3 mm, a thickness of 0.2 mm and it is composed by a mesh with grid of 80 μm and ribs with width of 70 μm. The proposed micro-filter is fabricated by micro injection moulding process adopting a steel mould manufactured by micro Electrical Discharge Machining process (micro EDM). Different polymeric materials (POM, HDPE, LCP), particularly indicated for the injection moulding applications due to their flowability and stability, are tested and evaluated in relation to the process replication capability. Since the polymer micro-filter is made of a complex grid of micro-ribs, the injection moulding process must ensure complete filling of the micro-parts, preventing any defects (i.e. premature solidification, incomplete filling, flash and air traps). To this aim, different system parameters configurations (melt and mould temperature, injection velocity, holding time and pressure, cooling time, pressure limit) are tested for obtaining acceptable part in all polymers grade. Finally, the component is dimensionally characterized by confocal microscopy and its filtration capacity is then verified. Although the feature complexity was high, the results showed that the object could be successfully replicated by filling completely the micro cavities with two of them: POM and HDPE. The most significant parameters influencing the part filling were the mould temperature and the injection velocity. These findings allow to further optimize the micro-injection process parameters to obtain a high quality product.

scholarly journals Micro Injection Moulding Process Parameter Tuning

Procedia CIRP ◽  
2015 ◽  
Vol 33 ◽  
pp. 400-405 ◽  
Author(s):  
Michael Packianather ◽  
Christian Griffiths ◽  
Wan Kadir
Keyword(s):  
Injection Moulding ◽  
Parameter Tuning ◽  
Process Parameter ◽  
Moulding Process ◽  
Micro Injection Moulding ◽  
Injection Moulding Process
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