Advanced Injection Molding Technologies

Frontmatter

1. Introduction to Injection Molding

Abstract

Injection molding is an important thermoplastic processing technique for producing plastic parts and products [1, 2]. Complete operation of injection molding requires an injection molding machine with a control unit, a properly clamped mold with a cavity or cavities that define(s) the part geometry, and a mold temperature control unit.

Shia-Chung Chen

2. Intelligent Control of the Injection Molding Process

Abstract

The ultimate goal of injection molding is to produce high-quality products consistently.¹ To achieve this, some key process variables closely related to the product quality need to be properly set and precisely controlled. Furthermore, safety and administrative issues need to be considered. A sophisticated controller has to be a complicated multiobjective multilayer system.

Yi Yang, Furong Gao

3. Water-Assisted Injection Molding

Abstract

Water-assisted injection molding (WAIM) [1, 2], an innovative injection-molding technology, has become one of the most important techniques for manufacturing hollow plastic parts. Despite having been patented in the 1930s, water-assisted injection- molding technology was not realized as a special process for industrial applications until the late 1990s by the research team at the Plastic Processing Institute (IKV) of Aachen University, Germany [3–5].

Shih-Jung Liu

4. Foam Injection Molding of Conductive-Filler/Polymer Composites

Abstract

Electrically conductive-filler/polymer composites (CPCs) are an emerging class of materials that offer a unique combination of properties that are unachievable otherwise. Such characteristics include light weight, ease of manufacture, a broad range of conductivity, and relatively high strength-to-weight ratio.

Amir Ameli, Chul B. Park

5. Water-Assisted Foaming: A New Improved Approach in Injection Molding

Abstract

In injection molding, the cooling time is the largest percentage of total cycle time because of the inherently low thermal conductivity of plastics. Decreasing the cooling time, which in turn increases the productivity, would adversely affect the part quality and dimensional stability, for example, the shrinkage, warpage, and mechanical properties.

Rachmat Mulyana, Jose M. Castro, L. James Lee

6. Variable Mold Temperature Technologies

Abstract

The cooling stage in injection molding accounts for about two-thirds of the total injection molding cycle. Therefore, minimizing the cooling time by using a low mold temperature to achieve high production efficiency is a great concern for injection molding operations. However, desirable part surface qualities such as high gloss, a lack of weld line or floating marks, and low residual stress require the part to be molded at relatively high mold temperatures.

Shia-Chung Chen

7. CAE for Advanced Injection Molding Technologies

Abstract

Injection molding is one of the most popular polymer processing methods and has been used to mass produce plastics products for many decades. However, due to increasingly stringent requirements and higher customer expectations, conventional injection molding cannot always meet all manufacturing specifications.

Rong-Yeu Chang, Chao-Tsai (CT) Huang

8. Injection Molding of Optical Products

Abstract

In 1933, after years of research and development, Rhom and Haas Company debuted the first batch of poly(methyl methacrylate) (PMMA), trade name Plexiglas^®, to explore its potential application in optics products such as instrument windows and shatterproof glass.

Pei-Jen Wang

9. Microinjection Molding

Abstract

Injection molding is one of the most common processes used in the plastics industry. Some of its advantages include high accuracy in replication, relatively short cycle times, and high productivity of complex parts. In recent years, injection-molded parts have consistently decreased in size and weight to meet industry demands.

Eusebio Cabrera, Jose M. Castro, Allen Y. Yi, L. James Lee

10. Mold Design/Manufacturing Navigation System with Knowledge Management

Abstract

Software and hardware are continually evolving and innovating, and newer techniques are always developing, but the time-consuming knowledge accumulation is a necessary process in the domain of engineering. Mold design/making encompasses many aspects, processes, methods, and details. Therefore, the inheritance and learning of knowledge usually proceed through a traditional mentoring system. However, this mode is subjective and time consuming and is likely to involve mistakes; thus, it is ripe for improvement.

Wen-Ren Jong

Backmatter