Functional Analysis Validation of Micro and Conventional Injection Molding Machines Performances Based on Process...

Area of Science:

• Materials Science
• Manufacturing Engineering
• Polymer Engineering

Background:

• Micro polymer parts are crucial in various industries, necessitating precise manufacturing methods.
• Conventional injection moulding (IM) and micro-injection moulding (µIM) are primary techniques for micro part production.
• Understanding the performance differences between IM and µIM is vital for optimizing micro-manufacturing.

Purpose of the Study:

• To conduct a functional analysis comparing the performance of IM and µIM for manufacturing a specific industrial component.
• To identify causal relationships between process phases, machine functions, and final product quality.
• To provide a data-driven comparison of the two manufacturing technologies.

Main Methods:

• Functional analysis was employed to deconstruct production cycles and machine functions.
• Experimental validation involved moulding micro medical parts from thermoplastic elastomer (TPE) using both IM and µIM with multi-cavity moulds.
• Produced parts were quantitatively assessed using precision weighing and high-accuracy optical measurements, with results analyzed via capability indexes.

Main Results:

• The functional analysis successfully mapped process phases and machine functions.
• Experimental data revealed distinct performance differences between IM and µIM.
• Capability indexes highlighted significant correlations between machine design and part quality.

Conclusions:

• Micro-injection moulding (µIM) technology significantly outperforms conventional injection moulding (IM) for micro-manufacturing.
• µIM meets the stringent accuracy and precision requirements characteristic of micro production.
• The study quantifies the link between machine technology and the quality of micro polymer parts.