Micro Injection Moulding High Accuracy Three-Dimensional Simulations and Process Control

Data analysis and simulations of micro‐moulding experiments have been conducted. Micro moulding simulations have been executed by implementing in the software the actual processing conditions. Various aspects of the simulation set‐up have been considered in order to improve the simulation accuracy (i.e. decrease deviations from experimental values): injection speed profile, cavity injection pressure, melt and mould temperatures, three‐dimensional mesh parameters, and material rheological characterization. Quality factors investigated for the quantitative comparisons were: short shot length, injection pressure profile, moulding mass and flow pattern. The importance of calibrated micro moulding process monitoring for an accurate implementation strategy of the simulation and its validation has been demonstrated. In fact, inconsistencies and uncertainties in the experimental data must be minimized to avoid introducing uncertainties in the simulation calculations. Simulations of bulky sub‐100 milligrams micro moulded parts have been validated and a methodology for accurate micro moulding simulations was established.