A Combined In-Mold Decoration and Microcellular Injection Molding Method for Preparing Foamed Products with Improved Surface Appearance

Injection moulding is a well-established replication process for the cost-effective manufacture of polymer-based components. The process has different applications in fields such as medical, automotive and aerospace. To expand the use of polymers to meet growing consumer demands for increased functionality, advanced injection moulding processes have been developed that modifies the polymer to create microcellular structures. Through the creation of microcellular materials, additional functionality can be gained through polymer component weight and processing energy reduction. Microcellular injection moulding shows high potential in creating innovation green manufacturing platforms. This review article aims to present the significant developments that have been achieved in different aspects of microcellular injection moulding. Aspects covered include core-back, gas counter pressure, variable thermal tool moulding and other advanced technologies. The resulting characteristics of creating microcellular injection moulding components through both plasticising agents and nucleating agents are presented. In addition, the article highlights potential areas for research exploitation. In particular, acoustic and thermal applications, nano-cellular injection moulding parts and developments of more accurate simulations.

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“…87 the mould insulator reducing the heat transfer coefficient, whilst the conventional mould surface remained constant. 89…”

Section: Mould Temperature Insulation Coatingsmentioning

confidence: 99%

Advances in microcellular injection moulding

Llewelyn

Rees

Griffiths

et al. 2020

Journal of Cellular Plastics

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“…At present, it is not possible to use CAD/CAM technology alone to manufacture objects with a fine internal structure [39,40]. Although injection molding can be used to manufacture peek implants with a definite shape, substitute models with a fine structure can be made by technicians, but the fine internal structure cannot be reconstituted [41,42]. Therefore, in the present study, we combined 3D printing and injection-molding technologies to fabricate peek specimens with an internal cross-linked structure, which completely reconstituted the structure designed with computer software.…”

Section: Discussionmentioning

confidence: 99%

Three-Dimensionally-Printed Polyether-Ether-Ketone Implant with a Cross-Linked Structure and Acid-Etched Microporous Surface Promotes Integration with Soft Tissue

Feng

Liu

et al. 2019

IJMS

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Polyether-ether-ketone (peek) is one of the most common materials used for load-bearing orthopedic devices owing to its radiolucency and favorable mechanical properties. However, current smooth-surfaced peek implants can lead to fibrous capsule formation. To overcome this issue, here, peek specimens with well-defined internal cross-linked structures (macropore diameters of 1.0–2.0 mm) were fabricated using a three-dimensional (3D) printer, and an acid-etched microporous surface was achieved using injection-molding technology. The cell adhesion properties of smooth and microporous peek specimens was compared in vitro through a scanning electron microscope (SEM), and the soft tissue responses to the both microporous and cross-linked structure of different groups were determined in vivo using a New Zealand white rabbit model, and examined through histologic staining and separating test. The results showed that the acid-etched microporous surface promoted human skin fibroblasts (HSF) adherence, while internal cross-linked structure improved the ability of the peek specimen to form a mechanical combination with soft tissue, especially with the 1.5 mm porous specimen. The peek specimens with both the internal cross-linked structure and external acid-etched microporous surface could effectively promote the close integration of soft tissue and prevent formation of fibrous capsules, demonstrating the potential for clinical application in surgical repair.

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“…In order to reduce the frozen layer, the use of a high mold temperature has yielded good results in reducing the filling pressure and clearly improving the melt flow length [ 11 , 12 , 13 ]. According to research on mold temperature control [ 14 , 15 , 16 , 17 , 18 ], this is a crucial aspect of plastic manufacturing in the field of injection molding. The quality of the part is improved with a high mold surface temperature, although with undesirable increases in both the cooling time and the cycle time.…”

Section: Introductionmentioning

confidence: 99%

Improving the Melt Flow Length of Acrylonitrile Butadiene Styrene in Thin-Wall Injection Molding by External Induction Heating with the Assistance of a Rotation Device

Minh

2021

Polymers

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In injection molding, the temperature control of the dynamic mold is an excellent method for improving the melt flow length, especially of thin-wall products. In this study, the heating efficiency of a novel heating strategy based on induction heating was estimated. With the use of this heating strategy, a molding cycle time similar to the traditional injection molding process could be maintained. In addition, this strategy makes it easier to carry out the heating step due to the separation of the heating position and the mold structure as well as allowing the ease of magnetic control. The results show that, with an initial mold temperature of 30 °C and a gap (G) between the heating surface and the inductor coil of 5 mm, the magnetic heating process can heat the plate to 290 °C within 5 s. However, with a gap of 15 mm, it took up to 8 s to reach 270 °C. According to the measurement results, when the mold heating time during the molding process increased from 0 to 5 s, the flow length increased significantly from 71.5 to 168.1 mm, and the filling percentage of the thin-wall product also increased from 10.2% to 100%. In general, the application of external induction heating (Ex-IH) during the molding cycle resulted in improved melt flow length with minimal increase in the total cycle time, which remained similar to that of the traditional case.

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A Combined In-Mold Decoration and Microcellular Injection Molding Method for Preparing Foamed Products with Improved Surface Appearance

Cited by 29 publications

References 26 publications

Advances in microcellular injection moulding

Advances in microcellular injection moulding

Three-Dimensionally-Printed Polyether-Ether-Ketone Implant with a Cross-Linked Structure and Acid-Etched Microporous Surface Promotes Integration with Soft Tissue

Improving the Melt Flow Length of Acrylonitrile Butadiene Styrene in Thin-Wall Injection Molding by External Induction Heating with the Assistance of a Rotation Device

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