Replication quality assessment and uncertainty evaluation of a polymer precision injection moulded component

Among all the recently born manufacturing technologies, precision injection moulding holds a central role, being the only replication process currently capable of accurately producing complex shaped polymer parts integrating micrometric features on a mass scale. In this scenario, a study on the replication quality of a polymer injection moulded precision component for telecommunication applications is presented. The effects of the process parameters on the component dimensional variation have been investigated using a statistical approach. Replication fidelity of produced parts has been assessed using a focus variation microscope with sub-micrometric resolution. Measurement uncertainty has then been evaluated, according to the GUM considering contributions from different process settings combinations and mould geometries. The analysis showed that the injection moulding manufacturing process and the utilized measurement chain are indeed capable of providing the high precision needed for the production. The calculated uncertainties are compatible with the imposed part requirements