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Experimental Validation of Injection Molding Simulations of 3D Microparts and Microstructured Components Using
Dario Loaldi1, Francesco Regi1, Federico Baruffi1
1Department of Mechanical Engineering, Technical University of Denmark, Building 427A, Produktionstorvet, DK-2800 Kgs Lyngby, Denmark.
Micromachines
|July 1, 2020
Summary
Micro-injection molding simulations predict part quality and optimize conditions. This study uses digital twin technology to forecast microfeature dimensions and replication behavior, enhancing manufacturing accuracy.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Computational Mechanics
Background:
- The growing demand for micro-molded products necessitates advanced simulation tools for process optimization.
- Digital twins are crucial for predicting part quality and establishing optimal manufacturing conditions in micro-injection molding.
Purpose of the Study:
- To utilize micro-injection molding process simulation for predicting feature dimensions, optimizing processes, and analyzing microfeature replication behavior.
- To investigate the impact of geometrical boundary effects on microfeature replication.
Main Methods:
- Virtual studies were conducted to predict micro-ring diameter and flash formation on micro-components.
- The influence of microstructure orientation on microcavity filling time was analyzed for components with micro grooves.
- Multiscale meshing and 3D modeling with generalized Navier-Stokes equations were employed for microfeature replication prediction.
Main Results:
- Outer diameter of a micro-ring was predicted within 10 µm accuracy.
- Flash formation was accurately simulated for a 0.1 mg micro-component.
- Microfeature replication in a Fresnel lens was predicted with 91% accuracy, analyzing features from 17-346 µm.
Conclusions:
- Micro-injection molding process simulations offer significant potential for optimizing the manufacturing of 3D microparts and microstructured components.
- The study highlights both the capabilities and limitations of current simulation approaches in micro-injection molding.
