Effect of process parameters on flow length and flash formation in injection moulding of high aspect ratio polymeric micro features

Abdelkhalik Eladl, Rania Mostafa, Aminul Islam, Dario Loaldi, Hassan Soltan, Hans N. Hansen, Guido Tosello*

*Corresponding author for this work

    Research output: Contribution to journalJournal articleResearchpeer-review

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    This paper reports an investigation of the effects of process parameters on the quality characteristics of polymeric parts produced by micro injection moulding (µIM) with two different materials. Four injection moulding process parameters (injection velocity, holding pressure, melt temperature and mould temperature) were investigated using Polypropylene (PP) and Acrylonitrile Butadiene Styrene (ABS). Three key characteristics of the mouldings were evaluated with respect to process settings and the material employed: part mass, flow length and flash formation. The experimentation employs a test part with four micro fingers with different aspect ratios (from 21 up to 150) and was carried out according to the Design of Experiments (DOE) statistical technique. The results show that holding pressure and injection velocity are the most influential parameters on part mass with a direct effect for both materials. Both parameters have a similar effect on flow length for both PP and ABS at all aspect ratios and have higher effects as the feature thickness decreased below 300 µm. The study shows that for the investigated materials the injection speed and packing pressure were the most influential parameters for increasing the amount of flash formation, with relative effects consistent for both materials. Higher melt and mould temperatures settings were less influential parameters for increasing the flash amount when moulding with both materials. Of the two investigated materials, PP was the one exhibiting more flash formation as compared with ABS, when corresponding injection moulding parameters settings for both materials were considered.
    Original languageEnglish
    Article number58
    Issue number2
    Number of pages19
    Publication statusPublished - 2018

    Bibliographical note

    This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).


    • Micro injection moulding
    • Design of experiments
    • Part mass
    • Flow length
    • Flash formation


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