Process Optimization for Injection Moulding of Passive Microwave Components

Steffen G. Scholz, Tobias Mueller, Leonardo Santos Machado, Matteo Calaon, Guido Tosello, Stéphane Dessors, Manfred Prantl, Nathan Miller

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The demand for micro components has increased during the last decade following the overall trend towards miniaturization. Injection moulding is the favoured technique for the mass manufacturing of micro components or larger parts with micro-structured areas due to its ability to cost effectively replicate very complex shapes, precise tolerances and in high numbers. In order to secure Europe’s leading role in the sector of micro-fabrication the capabilities of injection moulding need to be further developed.
In this research a product for telecommunication, a diplexer unit, has been manufactured utilizing the injection moulding process. A design of experiment study has been carried out, varying process parameters such as injection speed, holding pressure, mould- and barrel temperature. The replicated parts are characterized by measuring geometric features and the part weight. Using an evaluation algorithm for modelling, the influence of different moulding parameters on the final part quality was assessed. Firstly a process model and secondly a quality model has been calculated. The results shows that part quality can be controlled by monitoring characteristic numbers.
Original languageEnglish
Title of host publicationProceedings of the 11th International Conference on Multi-Material Micro Manufacture (4M2016) : co-organised with 10th International Workshop on Microfactories (IWMF2016)
PublisherResearch Publishing Services
Publication date2016
ISBN (Print)978-981-11-0749-8
Publication statusPublished - 2016
Event4M/IWMF 2016 Conference - Technical University of Copenhagen, Kgs. Lyngby, Denmark
Duration: 13 Sep 201615 Sep 2016


Conference4M/IWMF 2016 Conference
LocationTechnical University of Copenhagen
CityKgs. Lyngby
Internet address


  • Injection moulding
  • Process optimization
  • Accuracy
  • Metallization
  • Optical metrology

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