Best practice strategies for validation of micro moulding process simulation

Franco Costa (Invited author), Guido Tosello (Invited author), Ben Whiteside (Invited author)

Research output: Chapter in Book/Report/Conference proceedingArticle in proceedingsResearchpeer-review


Simulation programs in polymer micro replication technology are used for the same reasons as in conventional injection moulding. To avoid the risks of costly re-engineering, the moulding process is simulated before starting the actual manufacturing process. Important economic factors are the optimization of the moulding process and of the tool using simulation techniques. Therefore, in polymer micro manufacturing technology, software simulation tools adapted from conventional injection moulding can provide useful assistance for the optimization of moulding tools, mould inserts, micro component designs, and process parameters. In order to obtain reliable results, adapted simulations to micro moulding applications need to be validated by comparison with experimental results. Due to the miniaturized scale of the part and the extreme conditions of the process, accurate process monitoring is challenging and therefore software validation is affected by the availability of adequately precise experimental data. In this paper, an investigation on two different micro moulded parts is presented and issues relating to the use of experimental results for the validation of micro moulding simulations are discussed. Recommendations regarding sampling rate, meshing quality, filling analysis methods (micro short shots, flow visualization) and machine geometry modelling are given on the basis of the comparison between simulated and experimental results within the two considered study cases.
Original languageEnglish
Title of host publicationProceedings of PPE'09 : Polymer Process Engineering ‘09 Conference
EditorsPhil Coates, Prof.
Number of pages419
Place of PublicationBradford (United Kingdom)
PublisherUniversity of Bradford
Publication date2009
ISBN (Print)978-1-85143-262-2
Publication statusPublished - 2009
EventPolymer Process Engineering ‘09 Conference - Bradford, United Kingdom
Duration: 27 Oct 200928 Oct 2009


ConferencePolymer Process Engineering ‘09 Conference
Country/TerritoryUnited Kingdom
Internet address


  • validation
  • micro injecion moulding
  • process monitoring
  • process simulation


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