Functional Analysis Validation of Micro and Conventional Injection Molding Machines Performances Based on Process Precision and Accuracy for Micro Manufacturing

Matteo Calaon*, Federico Baruffi, Gualtiero Fantoni, Ilenia Cirri, Marco Santochi, Hans Nørgaard Hansen, Guido Tosello

*Corresponding author for this work

Research output: Contribution to journalJournal articleResearchpeer-review

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Abstract

Micro polymer parts can be usually manufactured either by conventional injection moulding (IM) or by micro-injection moulding (µIM). In this paper, functional analysis was used as a tool to investigate the performances of IM and µIM used to manufacture the selected industrial component. The methodology decomposed the production cycle phases of the two processes and attributed functions to parts features of the two investigated machines. The output of the analysis was aimed to determine casual chains leading to the final outcome of the process. Experimental validation of the functional analysis was carried out moulding the same micro medical part in thermoplastic elastomer (TPE) material using the two processes by means of multi-cavity moulds. The produced batches were assessed using a precision scale and a high accuracy optical instrument. The measurement results were compared using capability indexes. The data-driven comparison identified and quantified the correlations between machine design and part quality, demonstrating that the µIM machine technology better meets the accuracy and precision requirements typical of micro manufacturing productions.
Original languageEnglish
Article number1115
JournalMicromachines
Volume11
Issue number12
Number of pages20
ISSN2072-666X
DOIs
Publication statusPublished - 2020

Keywords

  • functional analysis
  • Micro-injection moulding
  • Machine design
  • Process capability

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