Optimization Study on the Two-Color Injection Molding Process of Medical Protective Goggles Based on the BP-SSA...

Area of Science:

• Polymer Science and Engineering
• Manufacturing Processes
• Computational Materials Science

Background:

• Two-color injection molding of medical goggles faces defects like warpage and debonding, hindering multi-performance requirements.
• Achieving high light transmittance, impact resistance, and chemical resistance is crucial for medical device functionality.
• Existing methods struggle to balance process parameters for optimal defect reduction and performance.

Purpose of the Study:

• To optimize the two-color injection molding process for medical goggles, minimizing defects like warpage deformation.
• To meet stringent multi-performance requirements including optical clarity, impact strength, and chemical resistance.
• To develop an integrated methodology combining material selection, simulation, and intelligent optimization for high-precision manufacturing.

Main Methods:

• Material selection using compatibility principles and Moldflow simulation (Apec 1745 PC for frame, Makrolon 2858 PC for lens).
• 3D simulation modeling with Moldflow, optimizing injection sequence, gating, and cooling systems.
• Orthogonal testing (L32) to gather data on process parameters (temperatures, pressures, times) and warpage.
• Development of a BP-SSA intelligent optimization model to predict and minimize warpage deformation.

Main Results:

• The BP-SSA model achieved a Mean Absolute Percentage Error (MAPE) of 2.28%, significantly outperforming a standalone BP neural network (14.36%).
• Optimal parameters identified: 130°C mold temp, 311°C/310°C melt temps, 83 MPa/70 MPa holding pressures, 14s/8s holding times.
• Optimized process reduced warpage deformation to 0.8956 mm (simulation) and 0.944 mm (measured), a 67.9% decrease from initial simulations.

Conclusions:

• The integrated "material selection-CAE simulation-orthogonal test-BP-SSA optimization" approach effectively reduces warpage in two-color injection molding.
• This methodology provides technical support for high-precision manufacturing of thin-walled, transparent, multi-material medical products.
• The optimized process successfully balances defect reduction with critical performance requirements for medical goggles.