On the applicability of micro-injection moulding simulations to multivariate integrated process/product optimization

F. Baruffi, M. Calaon, G. Tosello, R. Elsborg

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As in conventional injection moulding, process simulation of micro-injection moulding (μIM) is a powerful tool for the optimization of the design of mould, parts and process. However, the miniaturized scale of the micro products introduces relevant challenges in terms of both validation and accuracy of the simulation results. In the present work, a case study based on the μIM process of thermoplastic elastomer (TPE) micro rings for sensors applicationis treated. Moulding process simulations using Autodesk Moldflow Insight 2016® were applied with the aim of predicting the effects of the variation of mould temperature, melt temperature, injection speed and holding pressure on the part geometry. The outcomes of the simulations were directly compared to real parts based on high accuracy optical measurements. The numerical model was calibrated by fitting simulations results to experimental observations taking into account the measurement uncertainty. The calibrated model was validated against the effects of the process parameters and then used to carry out a virtual optimization. The results showed that simulations correctly predicted the effects of the four investigated process parameters on the part geometrical accuracy, opening the door to profitable μIM virtual experiments
Original languageEnglish
Title of host publicationProceedings of WCMNM 2018
EditorsJoško Valentinčič, Martin Byung-Guk Jun, Kuniaki Dohda, Stefan Dimov
Number of pages4
Publication date2018
ISBN (Electronic)978-981-11-2727-4
Publication statusPublished - 2018
Event2018 World Congress on Micro and Nano Manufacturing (WCMNM2018) - Remisens Hotel Metropol, Portorož, Slovenia
Duration: 18 Sep 201820 Sep 2018


Conference2018 World Congress on Micro and Nano Manufacturing (WCMNM2018)
LocationRemisens Hotel Metropol


  • Process simulations
  • Micro-injection moulding
  • TPE


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