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The Investigation of Novel Dynamic Packing Technology for Injection Molded Part Quality Control and Its Production

Yung-Hsiang Chang1,2,3, Shia-Chung Chen1,2, Yu-Hung Ting1,2,3

  • 1R&D Center for Smart Manufacturing, Chung Yuan Christian University, Taoyuan City 320314, Taiwan.

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|July 9, 2022
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Summary

This study introduces scientific packing pressure setup technology to enhance plastic injection molding. Dynamic control optimizes part quality and production stability, improving key metrics like shrinkage and warpage.

Keywords:
dynamic packing technologyinjection moldingquality control

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Polymer Processing

Background:

  • Injection molding is crucial for mass plastic production, offering complex shapes and rapid cycles.
  • Conventional methods rely heavily on labor and experience, lacking consistent quality control and defect-free adjustments.
  • Existing processes struggle with maintaining production stability and achieving defect-free outcomes in mass production.

Purpose of the Study:

  • To establish scientific packing pressure setup technology for optimizing molded part quality.
  • To enhance the stability of consecutive production runs in injection molding.
  • To investigate dynamic packing pressure control for improved quality and process consistency.

Main Methods:

  • Investigated dynamic packing pressure setup technology.
  • Evaluated its impact on key part qualities: tensile strength, shrinkage deviation, total shrinkage, and warpage.
  • Conducted pilot runs of 300 cycles comparing two packing pressure control methods.

Main Results:

  • Optimized packing pressure setup, leading to significant quality improvements.
  • Achieved up to 3.9% increase in tensile strength, 92.9% reduction in regional shrinkage deviation, 41.9% reduction in total shrinkage, and 9.2% reduction in warpage.
  • Dynamic packing pressure control improved weight replication by 54%, reduced total shrinkage by 23%, and enhanced warpage control by 12% over 300 cycles.

Conclusions:

  • Dynamic packing pressure setup technology effectively optimizes molded part quality.
  • This scientific approach stabilizes mass production quality and reduces defects.
  • The findings demonstrate a significant advancement in achieving consistent, high-quality plastic injection molding.