A study on replication and quality correlation of on-part and on-runner polymer injection molded micro features

Nikolaos Giannekas, Guido Tosello, Yang Zhang

    Research output: Contribution to conferencePaperResearchpeer-review

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    Abstract

    Injection molding is increasingly gaining place in manufacturing of polymer components as is can ensure a cost efficient production with short cycle times. To ensure the quality of the produced parts and the stability of the process it is essential to perform frequent metrological inspections. In contrast to injection molding’s short cycle time, a metrological quality control can require a significant amount of time. The late detection of the problem can result to high losses and scrap rate. This paper presents an alternative approach to process monitoring and part quality control with fast off/in-line metrology of physical part quality indicators (“Product Fingerprint”). The proposed approach is based on the concept of metrology applied to dedicated micro features, positioned on the runners, similar or equal to those in the part in order to access the quality of the produced plastic parts. A designed experiment was employed to map the experimental space and quantify the pillars replication depending on position and processing parameter combinations. The pillars were assessed and the main effects of the processing parameters, were calculated to reveal that the effects of process parameter change were similar in all measurement positions. Results showed that the product fingerprints have a correlation to the quality of on-part micro features. The concept can support the creation of a fast part quality monitoring system that has the potential to decrease the use of off-line time-consuming detailed metrology for part approval.
    Original languageEnglish
    Publication date2017
    Number of pages4
    Publication statusPublished - 2017
    Event2017 World Congress on Micro and Nano Manufacturing (WCMNM 2017) - Kaohsiung, Taiwan, Province of China
    Duration: 27 Mar 201730 Mar 2017

    Conference

    Conference2017 World Congress on Micro and Nano Manufacturing (WCMNM 2017)
    Country/TerritoryTaiwan, Province of China
    City Kaohsiung
    Period27/03/201730/03/2017

    Keywords

    • Precision injection moulding
    • Quality Control
    • Process monitoring

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