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Updated: May 10, 2025

A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars
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Utilizing Simulation Software to Develop Injection Molding Process Windows with High-Impact Polystyrene.

Travis O'Leary1, Rachmat Mulyana1, Jose M Castro1

  • 1Industrial and Systems Engineering, College of Engineering, Columbus Campus, The Ohio State University, Columbus, OH 43210, USA.

Polymers
|April 28, 2025
PubMed
Summary
This summary is machine-generated.

This study presents a new method for process engineers to create injection molding process windows using simulation software. This approach helps manufacturers achieve desired product performance and reduce defects.

Keywords:
controllable process variablesinjection moldingprocess windowsimulation

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Area of Science:

  • Polymer Science
  • Manufacturing Engineering
  • Computational Modeling

Background:

  • Injection molding simulation software is underutilized by process engineers.
  • Expanding simulation use to manufacturing groups requires practical methodologies.

Purpose of the Study:

  • Develop a methodology to construct injection molding process windows using simulation software predictions.
  • Tailor process windows for specific product performance measures and defect targeting.

Main Methods:

  • Testing combinations of controllable process variables in the filling and packing stages.
  • Utilizing high-impact polystyrene for experimental validation.
  • Developing a simulation-based methodology for process window construction.

Main Results:

  • Experimentally validated process windows demonstrated successful part production.
  • Simulation accurately predicted dimensional shrinkage within 1% of experimental results.
  • The methodology allows tailoring of process windows to manufacturer needs.

Conclusions:

  • The developed methodology enhances the application of simulation software for manufacturing groups.
  • Simulation software can confidently aid manufacturing operations in achieving acceptable part quality.
  • This approach builds confidence in using simulation for practical injection molding process control.