Modelling the filling behavior of micro structured plastic optical components

Research output: Contribution to conferencePaperResearchpeer-review


In the case of micro structured and freeform optics, such as Fresnel lenses, the challenges related to the filling of the samples address to formation of weld lines, cavity balance and mostly full replication of the part and its surface features. Even though simulation and modelling can help predict such errors, when dealing with micro structured components the multi-scale requirements of the problem become a challenge. Not only the model definition, but also more practical aspects, as model validation and the definition of the boundary conditions as meshing are time consuming, complex but necessary steps. In this research, modelling of the filling behavior of a micro structured optical component is performed and validated comparing Injection Molding simulation with measured Injection Molded parts. The adoption of different polymer dosages addresses the investigation on “short shots”, in this way the filling of the part could be investigated at different injection instances. The comparison encompasses both micro- and meso- scale quantities, such as the injection pressure measured at the screw, the part mass, and the height of the micro features. The results show that the adopted modelling solution is in accordance with the experimental results at both the geometrical scales.
Original languageEnglish
Publication date2019
Number of pages5
Publication statusPublished - 2019
Event2019 World Congress on Micro and Nano Manufacturing (WCMNM2019) - The Sheraton Raleigh Hotel, Raleigh, United States
Duration: 10 Sep 201912 Sep 2019


Conference2019 World Congress on Micro and Nano Manufacturing (WCMNM2019)
LocationThe Sheraton Raleigh Hotel
Country/TerritoryUnited States


  • Modelling
  • Injection Molding
  • Process Simulation
  • Fresnel lenses
  • Filling


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